92-24161-20 Rev. 11 RGFD Modulating Furnace Installaiton

Transcription

INSTALLATION AND OPERATION INSTRUCTIONS
CONTENTS
!
SECTION 1
INSTALLATION INSTRUCTIONS
SECTION 2
THERMOSTAT INSTRUCTIONS
SECTION 3
USER’S INFORMATION MANUAL
WARNING
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER
INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS
THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR
MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING,
EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
INSTALLER:
USE THE INFORMATION IN THIS BOOKLET TO
INSTALL THE FURNACE AND THE
FURNACE CONTROLLER. LOCATE THIS
BOOKLET ADJACENT TO THE UNIT AFTER
INSTALLATION.
USER:
KEEP THIS BOOKLET OF INFORMATION FOR
FUTURE REFERENCE.
92-24161-20-11
SUPERSEDES 92-24161-20-10
SECTION 1
FOR (-)GFD UPFLOW & (-)GGD DOWNFLOW
HIGH EFFICIENCY MODULATING
CONDENSING GAS FURNACES
92-24161-22-11
CONTENTS
Safety Information ....................................................................................................3
Installation Check List ..............................................................................................4
General Information .................................................................................................5
Location Requirements and Considerations............................................................6
Venting and Combustion Air Piping .......................................................................14
Non-Direct Vent Pipe Installation ...........................................................................16
Direct Vent Pipe Installation ...................................................................................20
Condensate Drain/Optional Neutralizer .................................................................29
Gas Supply and Piping ..........................................................................................33
Electrical Wiring......................................................................................................38
Accessories ............................................................................................................41
Installation w/Heat Pump Systems ........................................................................45
High Altitude Installations .......................................................................................50
Installation with Premium/High Efficiency Cooling Systems..................................53
Integrated Furnace Control ....................................................................................54
Start-Up Procedures ..............................................................................................57
Maintenance...........................................................................................................60
Troubleshooting......................................................................................................63
Wiring Diagram.......................................................................................................71
Installation Instructions are updated on a regular basis. This is done as product
changes occur or if new information becomes available. In this publication, an
arrow ➤ denotes changes from the previous edition or additional new material.
IMPORTANT: To insure proper installation and operation of this product, completely read all instructions prior to attempting to assemble, install, operate, maintain or repair this product. Upon unpacking of THE furnace, inspect all parts for
damage prior to installation and start-up.
2
SAFETY INFORMATION
!
WARNING
USE ONLY WITH TYPE OF GAS
APPROVED FOR THIS FURNACE. REFER TO THE FURNACE RATING PLATE.
!
WARNING
INSTALL THIS FURNACE ONLY
IN A LOCATION AND POSITION AS SPECIFIED IN THE
LOCATION REQUIREMENTS
AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS. PROVIDE ADEQUATE
COMBUSTION AND VENTILATION AIR TO THE FURNACE
SPACE AS SPECIFIED IN THE
VENTING SECTION OF THESE
INSTRUCTIONS.
!
WARNING
PROVIDE ADEQUATE COMBUSTION AND VENTILATION
AIR TO THE FURNACE SPACE
AS SPECIFIED IN THE COMBUSTION AND VENTILATION
AIR SECTION OF THESE
INSTRUCTIONS.
!
WARNING
COMBUSTION PRODUCTS
MUST BE DISCHARGED OUTDOORS. CONNECT THIS FURNACE TO AN APPROVED
VENT SYSTEM ONLY, AS
SPECIFIED IN VENT PIPE
INSTALLATION SECTION OF
THESE INSTRUCTIONS.
!
WARNING
DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!!
THIS FURNACE IS NOT
APPROVED FOR INSTALLATION IN A MOBILE HOME.
DOING SO COULD CAUSE
FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR
DEATH.
!
WARNING
NEVER TEST FOR GAS LEAKS
WITH AN OPEN FLAME. USE A
COMMERCIALLY AVAILABLE
SOAP SOLUTION MADE
SPECIFICALLY FOR THE
DETECTION OF LEAKS TO
CHECK ALL CONNECTIONS,
AS SPECIFIED IN GAS SUPPLY
AND PIPING SECTION OF
THESE INSTRUCTIONS.
!
WARNING
ALWAYS INSTALL FURNACE
TO OPERATE WITHIN THE
FURNACE'S INTENDED TEMPERATURE-RISE RANGE WITH
A DUCT SYSTEM WHICH HAS
AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED
IN DUCTING SECTION OF
THESE INSTRUCTIONS. SEE
ALSO FURNACE RATING
PLATE.
!
WARNING
WHEN A FURNACE IS
INSTALLED SO THAT SUPPLY
DUCTS CARRY AIR CIRCULATED BY THE FURNACE TO
AREAS OUTSIDE THE SPACE
CONTAINING THE FURNACE,
THE RETURN AIR SHALL
ALSO BE HANDLED BY
DUCT(S) SEALED TO THE
FURNACE CASING AND TERMINATING OUTSIDE THE
SPACE CONTAINING THE
FURNACE.
!
WARNING
WHEN THIS FURNACE IS
INSTALLED IN A RESIDENTIAL
GARAGE, IT MUST BE
INSTALLED SO THE BURNERS
AND IGNITION SOURCE ARE
LOCATED NO LESS THAN 18
INCHES ABOVE THE FLOOR.
THIS IS TO REDUCE THE RISK
OF IGNITING FLAMMABLE
VAPORS WHICH MAY
BE PRESENT IN A GARAGE.
ALSO, THE FURNACE MUST
BE LOCATED OR PROTECTED
TO AVOID PHYSICAL DAMAGE
BY VEHICLES. FAILURE TO
FOLLOW THESE WARNINGS
CAN CAUSE A FIRE OR
EXPLOSION, RESULTING IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
!
WARNING
USE OF THIS FURNACE IS
ALLOWED DURING CONSTRUCTION IF THE FOLLOWING TEMPORARY INSTALLATION REQUIREMENTS ARE
MET. INSTALLATION MUST
COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:
• PROPER VENT INSTALLATION;
• FURNACE OPERATING
UNDER THERMOSTATIC
CONTROL;
• RETURN AIR DUCT SEALED
TO THE FURNACE;
• AIR FILTERS IN PLACE;
• SET FURNACE INPUT RATE
AND TEMPERATURE RISE
PER RATING PLATE MARKING;
• MEANS FOR PROVIDING
OUTDOOR AIR REQUIRED
FOR COMBUSTION;
• RETURN AIR TEMPERATURE MAINTAINED
BETWEEN 55°F (13°C) AND
80°F (27°C); AND;
• CLEAN FURNACE, DUCT
WORK AND COMPONENTS
UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND
VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE,
TEMPERATURE RISE AND
VENTING, ACCORDING TO
THE INSTRUCTIONS.
3
INSTALLATION CHECK LIST
REFER TO INSTALLATION INSTRUCTIONS
GAS SUPPLY
Adequate pipe size
TERMINATIONS – DIRECT VENT
VERTICAL
Correct supply pressure (during furnace operation)
Intake – 12" min. above roof/snow level
Manifold pressure
Correct relationship – exhaust to intake
No gas leaks
ELECTRICAL
115 V.A.C. supply (Single Circuit)
Polarity observed
Furnace properly grounded (Earth ground)
Adequate wire size
VERTICAL – CONCENTRIC (RXGY-E03)
Intake – 12" min. above roof/snow level
HORIZONTAL – STANDARD (RXGY-D02, -D03)
12" min. above grade/snow level
HORIZONTAL – ALTERNATE (RXGY-D02, -D03 OR -D04)
FURNACE INSTALLATION
Adequate clearance to combustibles
Adequate clearance for service (at front)
DUCT STATIC PRESSURE
in. w.c. on heating speed
Above anticipated snow level
HORIZONTAL – CONCENTRIC (RXGY-E03)
Intake “Y” rotated above center
Exhaust sloped toward furnace
in. w.c. on cooling speed
Air temperature rise
VENTING – NON-DIRECT VENT (VERTICAL ONLY)
in. diameter – exhaust pipe
CONDENSATE LINE
Trap filled with water
ft. of pipe – exhaust
no. of elbows
Vented
Sloped toward drain
Condensate drain line hoses connected
and clamped
TERMINATION – NON-DIRECT VENT (VERTICAL ONLY)
12" min. above roof/snow level
Model #
Serial #
Freeze protection (if necessary)
Date of installation
______
Neutralizer (if needed)
HORIZONTAL – STANDARD
VENTING – DIRECT VENT
in. diameter – intake pipe
in. diameter – exhaust pipe
ft. of pipe – intake air
no. of elbows – intake air
ft. of pipe – exhaust pipe
no. of elbows – exhaust pipe
4
HORIZONTAL – ALTERNATE
Above anticipated snow level
GENERAL INFORMATION
The (-)GFD and (-)GGD series furnaces are design-certified by CSA for
use with natural and L.P. gases as
follows:
• As direct vent, central forced air
furnaces with all combustion air
supplied directly to the furnace
burners through a special air intake
system outlined in these instructions.
• As non-direct, central forced air furnace taking combustion air from
the installation area or using air
ducted from the outside.
Install this furnace in accordance with
the American National Standard
Z223.1 – latest edition entitled
“National Fuel Gas Code” (NFPA54,
90A and 90B) and requirements or
codes of the local utilities or other
authorities having jurisdiction. This is
available from the following:
CSA International - U.S.
8501 East Pleasant Valley Road
Cleveland, Ohio, 44131
National Fire Protection
Association, Inc.
Batterymarch Park
Quincy, MA 02269
CSA International - Canada
178 Rexdale Blvd.
Etobicoke (Toronto), Ontario,
Canada M9W-1R3
Canadian installations must be
installed in accordance with CSA,
local installation codes and
authorities having jurisdiction.
CSA is available from:
➤ FIGURE 2
FIGURE 1
UPFLOW FURNACE
DOWNFLOW/HORIZONTAL FURNACE
I678
ITEM
NO. PART NAME
ITEM
NO. PART NAME
ITEM
NO. PART NAME
1
CONDENSATE TRAP
14
TOP PLATE
1
GAS VALVE
2
DOOR SWITCH
15
BURNER
2
CAPACITOR
3
JUNCTION BOX
16
IGNITER
3
LOW PRESSURE SWITCH
4
TRANSFORMER
17
COMBUSTION AIR INLET
4
HIGH PRESSURE SWITCH
5
LOW PRESSURE SWITCH
18
GAS VALVE
5
BLOWER HOUSING
6
19
CAPACITOR
6
POWER FACTOR CHOKE
7
EXHAUST TRANSITION
20
INDUCED DRAFT BLOWER
7
BLOWER MOTOR
8
CONNECTOR
21
POWER FACTOR CHOKE
8
DOOR SWITCH
9
MAIN LIMIT
22
IGNITION CONTROL
9
JUNCTION BOX
10
EXHAUST AIR PIPE
23
INTEGRATED FURNACE CONTROL
10
11
VENT CAP PLUG
24
BLOWER MOTOR
11
HALC
12
FLAME SENSOR
25
R/A SENSOR
12
TOP PLATE
13
OVERTEMPERATURE SWITCH
26
BLOWER HOUSING
13
RETURN AIR SENSOR
ITEM
NO. PART NAME
14
15
16
17
18
19
20
21
22
23
24
25
26
27
VENT CAP PLUG
EXHAUST AIR PIPE
TRANSFORMER
IGNITION CONTROL
CONNECTOR
EXHAUST TRANSITION
MAIN LIMIT
CONDENSATE TRAP
IGNITER
BURNER
FLAME SENSOR
5
LOCATION REQUIREMENTS AND CONSIDERATIONS
GENERAL INFORMATION
! CAUTION
DO NOT USE THIS FURNACE
DURING CONSTRUCTION IF
AIR LADEN CORROSIVE COMPOUNDS ARE PRESENT SUCH
AS CHLORINE AND FLUORINE.
OTHERWISE, PROVISIONS
MUST BE TAKEN TO PROVIDE
CLEAN, UNCONTAMINATED
COMBUSTION AND VENTILATION AIR TO THE FURNACE.
FURNACE COMBUSTION AND
VENTILATION AIR CONTAMINATED WITH THESE COMPOUNDS FORMS ACIDS DURING COMBUSTION WHICH
CORRODES THE HEAT
EXCHANGER AND COMPONENT PARTS. SOME OF THESE
CONTAMINANTS ARE FOUND
IN, BUT NOT LIMITED TO, PANELING, DRY WALL, ADHESIVES,
PAINTS, STAINS, VARNISHES,
SEALERS, AND MASONRY
CLEANING MATERIALS.
!
WARNING
DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!!
THIS FURNACE IS NOT
APPROVED FOR INSTALLATION
IN A MOBILE HOME. DOING SO
COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
!
WARNING
WHEN THIS FURNACE IS
INSTALLED IN A RESIDENTIAL
GARAGE, IT MUST BE
INSTALLED SO THE BURNERS
AND IGNITION SOURCE ARE
LOCATED NO LESS THAN 18
INCHES ABOVE THE FLOOR.
THIS IS TO REDUCE THE RISK
OF IGNITING FLAMMABLE
VAPORS WHICH MAY
BE PRESENT IN A GARAGE.
ALSO, THE FURNACE MUST BE
LOCATED OR PROTECTED TO
AVOID PHYSICAL DAMAGE BY
VEHICLES. FAILURE TO FOLLOW THESE WARNINGS CAN
CAUSE A FIRE OR EXPLOSION,
RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
1. IMPORTANT: When installing the
-GGD furnace in the horizontal
configuration, a special kit must
be used to convert the furnace for
horizontal installation. The necessary kits are listed here.
2. IMPORTANT: If installing the unit
over a finished ceiling or living
area, be certain to install an auxiliary condensate drain pan under
the entire unit. Extend this auxiliary
drain pan under any evaporator
coil installed with the furnace and
the open portion of the condensate
drain assembly. See “Condensate
Drain/Neutralizer” section for more
details.
3. IMPORTANT: If using a cooling
evaporator coil with this furnace.
Be sure the air passes over the
heat exchanger before passing
over the cooling coil. The cooled
air passing over the warm ambient
air inside the heat exchanger
tubes can cause condensation
inside the tubes resulting in corrosion and eventual failure.
4. IMPORTANT: Install the furnace
level. If it is not level, condensate
cannot drain properly, possibly
causing furnace shut down.
NOTE: These furnaces are approved
for installation in attics, as well as
alcoves, utility rooms, closets and
crawlspaces. Make provisions to prevent freezing of condensate.
5. IMPORTANT: If this furnace is
installed in a garage, attic or any
other unconditioned space, a selfregulating heat tape must be
installed around the condensate
The heat tape should meet the
following requirements:
a. The heat tape must be UL listed.
b. Install the heat tape per the
manufacturer’s instructions for
the entire length of drain pipe
in the unconditioned space.
c. The heat tape should be rated
at 3 or 5 watts per foot at
120V.
6. IMPORTANT: If installing in a
utility room, be sure the door is
wide enough to:
a. allow the largest part of the
furnace to pass; or
b. allow any other appliance
(such as a water heater)
to pass.
7. Install the furnace level and
plumb. If it is not level, condensate cannot drain properly, possibly causing furnace to shut
down.
IMPORTANT: Do not attempt to twin
the modulating furnace. The characteristics of the ecm2 blower motor
preclude twinning applications.
!
CAUTION
LOCATE AND REMOVE THE SHIPPING BRACKET FROM THE SIDE
OF THE BLOWER HOUSING
BEFORE OPERATING UNIT. SEE
FIGURE 5.
FIGURE 3
HORIZONTAL FURNACE WITH HEAT TAPE ON CONDENSATE TRAP
SUPPLY
AIR
DRAIN
PIPE
HEAT
TAPE
TRAP
6
trap and along the entire length
of the condensate drain in the
unconditioned space.
HORIZONTAL
FURNACE
CONVERSION
MODEL
KIT
(-)GGD-06 . . . . . . . . RXGY-G01
(-)GGD-07 . . . . . . . . RXGY-G02
(-)GGD-09 . . . . . . . . RXGY-G03
(-)GGD-10 . . . . . . . . RXGY-G04
(-)GGD-12 . . . . . . . . RXGY-G05
RETURN
AIR
FIGURE 4
HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS
GAS
PIPE
INTAKE
VENT
ELECTRICAL
CONDUIT
SUPPLY
AIR
EXHAUST
VENT
TRAP
!
RETURN
AIR
CAUTION
THIS FURNACE IS NOT
APPROVED OR RECOMMENDED
FOR INSTALLATION ON ITS BACK,
WITH ACCESS DOORS FACING
UPWARDS, OR WITH SUPPLY AIR
DISCHARGING TO THE RIGHT
HAND SIDE WHEN FACING THE
FRONT OF THE FURNACE.
SEE FIGURES 3 AND 4 FOR PROPER INSTALLATION OF HORIZONTAL MODELS.
FIGURE 5
REMOVING SHIPPING BRACKET
HORIZONTAL
FURNACE
CONVERSION
MODEL
KIT
(-)GGD-06 . . . . . . . . . . RXGY-G01
(-)GGD-07 . . . . . . . . . . RXGY-G02
(-)GGD-09 . . . . . . . . . . RXGY-G03
(-)GGD-10 . . . . . . . . . . RXGY-G04
(-)GGD-12 . . . . . . . . . . RXGY-G05
Upflow furnaces are shipped with
a bottom closure panel installed.
When bottom return air is used,
remove the panel by removing the
two screws attaching the panel to
the front base angle. See filter section for details.
The design of forced air furnaces with
models as listed in the tables under
Figures 6, 7 and 8 are certified by CSA
Laboratories for the clearances to
combustible materials shown in inches.
1. Select a site in the building near
the center of the proposed, or
existing, duct system.
2. Give consideration to the vent
system piping when selecting the
furnace location. Vent from the
furnace to the termination with
minimal length and elbows.
3. Locate the furnace near the
existing gas piping. If running a
new gas line, locate the furnace
to minimize the length and
elbows in the gas piping.
4. Locate the furnace to maintain
proper clearance to combustibles
as shown in Figures 4 & 5.
See name/rating plate and clearance
label for specific model number and
clearance information.
Service clearance of at least 24 inches
is recommended in front of
all furnaces.
FOR PURPOSES OF SERVICING
THIS APPLIANCE, ACCESSIBILITY
CLEARANCES, WHERE GREATER,
SHOULD TAKE PRECEDENCE
OVER FIRE PROTECTION CLEARANCES.
!
92-24379-01
CLEARANCE ACCESSIBILITY
IMPORTANT: When installing the
-GGD furnace in the horizontal configuration, a special kit must be used
to convert the furnace for horizontal
installation. The necessary kits are
listed here.
fied for installation on combustible
(wood only) floors. -GGD furnaces
mounted in the downflow configuration may be installed on a cased
evaporator coil mounted on a combustible (wood only) floor or (for
installations without an evaporator
coil) installed on a special combustible floor base mounted to a
combustible (wood only) floor. The
necessary floor base for installing a
-GGD furnace in the downflow configuration to a combustible (wood
only) floor is an accessory sold
through finished goods. Following
is a list of floor base models by furnace input size.
-GGD Furnace
Combustible
BTU’s
Floor Base
60, 75
RXGC-B17
90, 105
RXGC-B21
120
RXGC-B24
WARNING
FURNACES MUST NOT BE
INSTALLED DIRECTLY ON CARPET,
TILE OR OTHER COMBUSTIBLE
MATERIAL. INSTALLATION ON A
COMBUSTIBLE MATERIAL OTHER
THAN WOOD FLOORING MAY
RESULT IN FIRE CAUSING DAMAGE,
PERSONAL INJURY OR DEATH.
-GGD FURNACES CONFIGURED
FOR DOWNFLOW INSTALLATIONS
MAY NOT BE INSTALLED DIRECTLY
TO A COMBUSTIBLE FLOOR. A SPECIAL FLOOR BASE IS REQUIRED.
-GFD upflow furnaces and -GGD furnaces mounted in the horizontal
configuration are designed and certi-
SITE SELECTION
!
WARNING
COMBUSTIBLE MATERIAL MUST
NOT BE PLACED ON OR AGAINST
THE FURNACE JACKET. THE
AREA AROUND THE FURNACE
MUST BE KEPT CLEAR AND FREE
OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND
OTHER FLAMMABLE VAPORS
AND LIQUIDS. PLACEMENT OF
COMBUSTIBLE MATERIALS ON,
AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN
EXPLOSION OR FIRE RESULTING
IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THE
HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE
AREA MUST NOT BE USED AS A
BROOM CLOSET OR FOR ANY
OTHER STORAGE PURPOSES.
7
FIGURE 6
PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS
AO39201
8
FIGURE 7
DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, HORIZONTAL MODELS
IMPORTANT: THIS FURNACE MAY
ONLY BE INSTALLED SO AS WHEN
FACING THE FRONT OF THE FURNACE, SUPPLY AIR IS DISCHARGED ON THE LEFT HAND
SIDE.
9
FIGURE 8
DOWNFLOW MODELS
(Downflow Configuration)
DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, DOWNFLOW MODELS
A084901.S01
JWR 7-21-99
10
DUCTING
Proper airflow is required for the correct
operation of this furnace.
Too little airflow can cause erratic operation and can damage the heat
exchanger. The duct system must carry
the correct amount of air for heating
and cooling if summer air conditioning
is used.
Size the ducts according to acceptable
industry standards and methods. The
total static pressure drop of the air distribution system should not exceed 0.2"
w.c.
!
WARNING
NEVER ALLOW THE PRODUCTS
OF COMBUSTION FROM THE
FLUE TO ENTER THE RETURN
AIR DUCTWORK OR THE CIRCULATED AIR SUPPLY. ALL RETURN
DUCTWORK MUST BE ADEQUATELY SEALED AND
SECURED TO THE FURNACE
WITH SHEET METAL SCREWS;
AND JOINTS, TAPED. SECURE
ALL OTHER DUCT JOINTS WITH
APPROVED CONNECTIONS AND
SEAL AIRTIGHT. WHEN A FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH
THE BOTTOM, IT MUST BE
SEALED AIRTIGHT BETWEEN
THE FURNACE AND THE
RETURN AIR PLENUM. THE
FLOOR OR PLATFORM MUST
PROVIDE PHYSICAL SUPPORT
OF THE FURNACE WITHOUT
SAGGING, CRACKS, OR GAPS
AROUND THE BASE, PROVIDING
A SEAL BETWEEN THE SUPPORT
AND THE BASE.
FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM
BEING CIRCULATED INTO THE
LIVING SPACE CAN CREATE
POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON
MONOXIDE POISONING THAT
COULD RESULT IN PERSONAL
INJURY OR DEATH.
DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR
SUPPLY DUCTWORK TO OR
FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS A
FIREPLACE INSERT, STOVE, ETC.
DOING SO MAY RESULT IN FIRE,
CARBON MONOXIDE POISONING,
EXPLOSION, PERSONAL INJURY
OR PROPERTY DAMAGE.
IMPORTANT: Some high efficiency filters
have a greater than normal resistance to
airflow. This can adversely affect furnace
operation. Be sure to check airflow if
using any filter other than the factory-provided filter.
UPFLOW UNITS
1. Position the unit to minimize long
runs of duct or runs of duct with
many turns and elbows.
!
WARNING
UPFLOW FURNACE: A SOLID METAL
BASE PLATE MUST BE INSTALLED IN
THE FURNACE BOTTOM WHEN
USING SIDE AIR RETURN. FAILURE
TO INSTALL A BASE PLATE COULD
CAUSE THE PRODUCTS OF COMBUSTION TO CIRCULATE INTO THE
LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS,
INCLUDING CARBON MONOXIDE
POISONING OR DEATH.
2. Open the return air compartment.
a. If using side return air, do not
remove the bottom base.
b. Cut an opening in the side .
The opening should be cut the
full width of the knockouts on
the unit.
NOTE: When using side
return, return air plenums,
RXGR-C17B, C21B and C24B
are available from the factory.
c. Remove the bottom base, if
using bottom return air.
Remove the panel by removing the two screws attaching
the base to the front base
angle. See Figure 6.
NOTE: Where the maximum
airflow is 1800 CFM or more,
both sides or the bottom must
be used for return air.
3. Connect the return duct or return
air cabinet to the unit. Make the
connection air tight to prevent
entraining combustion gases from
an adjacent fuel-burning appliance.
4. Be sure to have adequate
space for the unit filter.
NOTE: DO NOT take return air
from bathrooms, kitchens, furnace
rooms, garages, utility or laundry
rooms, or cold areas. DO NOT
use a rear air return.
5. If summer air conditioning is
desired, position the indoor coil on
the top of the unit. Insure that no
air can bypass this coil.
6. Connect the supply air plenum to
the furnace plenum opening.
IMPORTANT: If a flexible duct
connector must be used, it MUST
be rated for a minimum temperature of 250°F. continuous.
FIGURE 9
BOTTOM PANEL REMOVAL
NOTE: FILTER AND FILTER-ROD ARE SHIPPED
ON TOP OF SOLID BOTTOM. REMOVE FILTER
AND FILTER ROD TO ACCES SOLID BOTTOM
542201-B1
11
DOWNFLOW UNITS
runs of duct or runs of duct with
many turns and elbows.
2. If summer air conditioning is desired,
position the indoor coil on the bottom
of the unit. Insure that no air can
bypass this coil.
3. If installing on a combustible floor
and not using an air conditioning
plenum, install the special non-combustible floor base. See Figure 7.
! WARNING
THE DOWNFLOW/HORIZONTAL
FURNACE DESIGN IN DOWNFLOW
MODE IS CERTIFIED FOR INSTALLATION ON A NON-COMBUSTIBLE
FLOOR. USE THE SPECIAL BASE
SPECIFIED ON THE FURNACE
CLEARANCE LABEL. FAILURE TO
INSTALL THE SPECIAL BASE MAY
RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH. THIS SPECIAL BASE IS
SHIPPED FROM THE FACTORY AS
AN ACCESSORY.
runs or runs with many turns and
elbows.
2. If summer air conditioning is desired,
position the indoor coil on the left
end of the unit. Insure that no air can
bypass this coil.
3. Connect the furnace to the supply air
plenum.
4. Connect the return air ducting to the
return air opening at the right end of
the unit. Make the connection air
tight to prevent entraining combustion gases from an adjacent fuelburning appliance.
5. Be sure to have adequate space
for the unit filter.
FIGURE 10
COMBUSTIBLE FLOOR BASE
4. Connect the furnace to the supply
air plenum.
5. Connect the return air ducting to
the return air opening at the top of
the unit. Make the connection air
tight to prevent entraining combustion gases from an adjacent fuelburning appliance.
6. Be sure to have adequate space
for the unit filter.
from bathrooms, kitchens, furnace
rooms, garages, utility or laundry
rooms, or cold areas.
HORIZONTAL UNITS
IMPORTANT: This furnace may only be
installed so as when facing the front of
the furnace, supply air is discharged on
the left hand side.
-GGD furnace in the horizontal configuration, a special kit must be used to
convert the furnace for horizontal installation. The necessary kits are listed
here.
HORIZONTAL
FURNACE
CONVERSION
MODEL
KIT
(-)GGD-06 . . . . . . . . . . RXGY-G01
(-)GGD-07 . . . . . . . . . . RXGY-G02
(-)GGD-09 . . . . . . . . . . RXGY-G03
(-)GGD-10 . . . . . . . . . . RXGY-G04
(-)GGD-12 . . . . . . . . . . RXGY-G05
12
FIGURE 11
SUPPLY AIR SENSOR TERMINALS
from bathrooms, kitchens, furnace rooms, garages, utility or
laundry rooms, or cold areas.
Return air can come from : (1)
outside the building, (2) from return
air ducting from several inside rooms,
or (3) a combination of the two.
When using outside air, design and
adjust the system to maintain a
return air temperature above 50°F
during the heating season. If return
air combes from both inside and outside the building, design the ducting
system with a diverting damper so
that the volume of return air entering
the furnace equals that which would
normally enter through the return air
intake of the furnace. Any duct opening
pulling return air from the outside must
not be any higher nor closer than 10
feet to the furnace exhaust vent.
SUPPLY AIR SENSOR
Each furnace comes shipped from the
factory with a supply air sensor. Install
the sensor, in the supply air plenum
trunk, with two, field supplied, #8 sheet
metal screws, using the following guidelines:
1. 12” downstream of the evaporator
coil, if installed.
2. If no evaporator coil is used locate
the sensor at least 18” downstream
of the furnace outlet. Always locate
the supply air sensor out of direct
line of sight of the heat exchanger
tubes, if possible.
NOTE: In downflow circumstances
where building construction does not
allow for the placement of the sensor to
fall within these parameters, the supply
air sensor should not be connected.
This means that the furnace will run
under default parameters. When running under default parameters, the “82”
code will appear for 1.5 minutes. After
that the fault code will be stored in the
control board’s memory and will show
upon power cycling. Default airflow
parameters can be manually adjusted.
See section discussing Integrated
Furnace Control (IFC) board in this
manual.
3. Attach the supply air sensor wires
onto the terminals marked “SA
Sensor” on the integrated furnace
control board (See Figure 5).
NOTE: Improper placement of the
supply air sensor can adversely
affect furnace temperature rise.
13
VENTING AND COMBUSTION AIR PIPING
GENERAL INFORMATION
!
WARNING
READ AND FOLLOW ALL
INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY
VENT THIS FURNACE OR PROTECT IT FROM INADEQUATE
COMBUSTION AIR CAN CAUSE
CARBON MONOXIDE POISONING, AN EXPLOSION OR FIRE,
RESULTING IN PROPERTY
OR DEATH.
OVER TEMPERATURE
SAFETY SWITCHES
Furnaces are equipped with safety
switches in the burner compartment to
protect against over temperature conditions. If a switch is tripped it must be
manually reset.
!
WARNING
DO NOT JUMPER OVERTEMPERATURE SAFETY SWITCHES!
IF ONE OF THESE OVER TEMPERATURE SWITCHES SHOULD
TRIP, CALL A QUALIFIED
INSTALLER, SERVICE AGENCY
OR THE GAS SUPPLIER. DO
NOT RESET THE SWITCHES
WITHOUT TAKING CORRECTIVE
ACTION. FAILURE TO DO SO
CAN RESULT IN CARBON
MONOXIDE POISONING OR
DEATH. IF THIS UNIT IS
INSTALLED IN A CLOSET, THE
DOOR MUST BE CLOSED WHEN
MAKING THIS CHECK.
REPLACE THE OVER TEMPERATURE SAFETY SWITCHES ONLY
WITH THE IDENTICAL
REPLACEMENT PART.
14
INSTALLATION WITH
PRE-EXISTING VENT
SYSTEMS
When the installation of this furnace
replaces an existing furnace that is
removed from a vent system serving
other appliances (such as a water
heater), the existing vent system is likely
to be too large to properly vent the
remaining attached appliances.
Follow the steps below with each appliance remaining connected to the original common vent system. Place the
appliance to be tested in operation,
while the other appliances remaining
connected to the common vent system
are not in operation. Test the operation
of each appliance individually by the following method.
1. Permanently seal any unused
openings in the common venting
system.
2. Visually inspect the venting system
for proper size and horizontal pitch
and determine that there is no
blockage, restriction, leakage, corrosion or other deficiencies which
could cause an unsafe condition.
3. If practical, close all building doors,
windows and all doors between the
space where the appliances
remaining connected to the common venting system are located.
Turn on clothes dryers and any
appliance not connected to the
common venting system. Turn on
any exhaust fans, such as range
hoods and bathroom exhausts, so
they will operate at maximum
speed. Do not operate a summer
exhaust fan. Close fireplace
dampers.
4. Follow the lighting instructions.
Place the appliance being inspected into operation. Adjust the thermostat so the appliance will operate
continuously.
5. Test for spillage at the draft hood
relief opening after 5 minutes of
main burner operation. Use the
flame of a match or candle, or
smoke from a cigarette, cigar
or pipe.
6. After it has been determined that
each appliance that remains connected to the common venting
system properly vents (when
tested as outlined above), return
doors, windows, exhaust fans,
fireplace dampers and any other
gas-burning appliance to their
previous conditions of use.
7. If improper venting is observed
during any of the above tests,
resize the common venting system. Refer to latest edition of the
National Fuel Gas Code ANSI
Z223.1, or the CSA-GAMA venting tables for Category I furnaces.
NOTE: Schedule 40 ABS-DWV
pipe and fittings may be used as
an alternate to PVC pipe for the
combustion air inlet and vent
pipes.
NOTE: Cellular core PVC is also
approved for use. It must be
schedule 40 PVC-DWV cellular
pipe manufactured under ASTM
F-891.
JOINING
PIPE AND FITTINGS
!
WARNING
PVC SOLVENT CEMENTS AND
PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE
VENTILATION AND DO NOT
ASSEMBLE COMPONENTS
NEAR HEAT SOURCE OR AN
OPEN FLAME. DO NOT
SMOKE. AVOID SKIN OR EYE
CONTACT. OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS. FAILURE TO FOLLOW
THESE GUIDELINES MAY
RESULT IN FIRE, EXPLOSION
OR ASPHYXIATION CAUSING
All pipe, fittings, solvent cement,
primers and procedures must conform
to American National Standard
Institute and American Society for
Testing and Materials (ANSI/ASTM)
standards in the U.S.
Pipe and Fittings - ASTM-D1785,
D2466, D2665, D2231, D2661, and
F628
PVC Primer and Solvent Cement ASTM-D2564
ABS Pipe and Fittings - Use ABS
Primer and Solvent Cement D2235
Procedure for Cementing Joints ASTM-D2855
In Canada all combustion air and vent
pipe must be CSA- or ULC-certified
Schedule 40 PVC, PVC-DWV or
ABS-DWV.
IMPORTANT: The plastic combustion
air and venting components are
MADE of PVC. If using ABS piping,
ensure that the solvent cement is
compatible for joining PVC to ABS
components or use a mechanical connection that can withstand the vent
temperatures and is corrosion resistant.
CEMENTING JOINTS
Properly seal all joints in the PVC vent
using the following materials and procedures:
PVC CLEANER-PRIMER AND
PVC MEDIUM-BODY SOLVENT
CEMENT
IMPORTANT: After cutting pipe, remove
all ragged edges and burrs. This is
important to prevent increase in pressure drop throughout the system.
1. Cut pipe end square. Chamfer edge
of pipe. Clean fitting socket and
pipe joint area of all dirt, grease and
moisture.
2. After checking pipe and socket for
proper fit, wipe socket and pipe with
cleaner-primer. Apply
a liberal coat of primer to inside surface of socket and outside of pipe.
READ INSTRUCTIONS INCLUDED
WITH THE PRIMER FOR PROPER
INSTALLATION.
3. Apply a thin coat of cement evenly
in the socket. Quickly apply a heavy
coat of cement to the pipe end and
insert pipe into fitting with a slight
twisting movement until it bottoms
out.
NOTE: Cement must be fluid; if not,
recoat.
4. Hold the pipe in the fitting for 30
seconds to prevent the tapered
socket from pushing the pipe out of
the fitting.
5. Wipe all excess cement from the
joint with a rag. Allow 15 minutes
before handling. Cure time varies
according to fit, temperature and
humidity.
NOTE: Stir the solvent cement frequently while using. Use a natural
bristle, one inch wide brush or the
applicator supplied with the can.
IMPORTANT: For Proper Installation
DO NOT use solvent cement that has
become curdled, lumpy or thickened.
DO NOT thin. Observe shelf precautions printed on containers. For application below 32°F, use only low-temperature-type solvent cement.
For correct installation of the vent
pipe, follow the instructions provided
by the manufacturers of the pipe,
primer and solvent.
15
NON-DIRECT VENT PIPE INSTALLATION
(FOR VERTICAL TERMINATIONS ONLY)
COMBUSTION AIR
!
WARNING
ALWAYS PROVIDE THIS FURNACE AND ANY OTHER FUEL
BURNING APPLIANCE WITH
ENOUGH FRESH AIR FOR
PROPER COMBUSTION AND
VENTILATION OF THE FLUE
GASES. MOST BUILDING
CODES REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO
THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE
DEATH FROM CARBON
MONOXIDE POISONING.
Provide adequate facilities for combustion and ventilation air in accordance with section 5.3, Air for
Combustion and Ventilation of the
National Fuel Gas Code, ANSI
Z223.1 - latest edition; CAN/CGA
B149.1 and .2, or applicable provisions of the local building codes.
These combustion and ventilation
facilities must not be obstructed.
IMPORTANT: Air for combustion and
ventilation must not come from a
corrosive atmosphere. Any furnace
failure due to corrosive elements in
the atmosphere is excluded from
warranty coverage.
The following types of installation (but
not limited to the following) REQUIRE
OUTDOOR AIR for combustion, due
to chemical exposures:
• Commercial buildings
• Buildings with indoor pools
• Furnaces installed in laundry
rooms
• Furnaces in hobby or craft rooms
• Furnaces installed near chemical
storage areas.
Exposure to the following substances
in the combustion air supply (but not
limited to the following) also
REQUIRE OUTDOOR AIR for combustion:
WARNING
ALL FURNACE INSTALLATIONS
MUST COMPLY WITH THE
NATIONAL FUEL GAS CODE AND
LOCAL CODES TO PROVIDE
ADEQUATE COMBUSTION AND
VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN
RESULT IN EXPLOSION, FIRE,
PROPERTY DAMAGE, CARBON
MONOXIDE POISONING, PERSONAL INJURY OR DEATH.
Combustion air requirements are
determined by whether the furnace
is in an open (unconfined) area or in
a confined space such as a closet or
small room.
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine-based swimming pool
chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon Tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers,
varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Anti-static fabric softeners for
clothes dryers
• Masonry acid washing materials
Combustion air must be free of acid
forming chemicals such as sulphur,
fluorine, and chlorine. These elements are found in aerosol sprays,
detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants and many
other commercial and household
products. Vapors from these products
when burned in a gas flame form acid
compounds. The acid compounds
increase the dew point temperature
of the flue products and produce
highly corrosive condensate.
16
!
FURNACE LOCATED IN AN
UNCONFINED SPACE
Using indoor air for combustion.
An unconfined space must have at
least 50 cubic feet for each 1,000
BTUH of the total input for all
appliances in the space. Here are a
few examples of the room sizes
required for different inputs. The
sizes are based on 8 foot ceilings.
See Table 1.
TABLE 1
UNCONFINED SPACE DIMENSIONS
BTUH Minimum Sq. Feet
Input With 8 foot Ceiling
60,000
375
75,000
469
90,000
563
105,000
657
120,000
750
Typical Room Size
15' x 25' OR 19' x 20'
15' x 32' OR 20' x 24'
20' x 28' OR 24' x 24'
20' x 33' OR 26' x 25'
25' x 30' OR 24' x 32'
If the open space containing the furnace is in a building constructed to
severely limit outside air infiltration
(contemporary energy efficient construction methods), outside air may
still be required for the furnace to
operate and vent properly. Outside
air openings should be sized the
same as for a confined space.
FURNACE LOCATED IN A
CONFINED SPACE.
A confined space (any space smaller than shown before as “unconfined”) must have openings into
the space, which are located in
accordance with the requirements set forth in the following
subsections A and B. The openings must be sized by how they
connect to the heated area or to the
outside, and by the input of all
appliances in the space.
If the confined space is within a
building with tight construction,
combustion air must be taken from
outdoors or areas freely communicating with the outdoors.
A. USING INDOOR AIR FOR
COMBUSTION
IMPORTANT: DO NOT take air from
a heated space with a fireplace,
exhaust fan or other device that may
produce a negative pressure.
If combustion air is taken from the
heated area (see Figure 12), the
openings must each have at least
100 square inches of free area.
Each opening must have at least
one square inch of free area for
each 1,000 BTUH of total input in
the space. See Table 2.
TABLE 2
Free Area
Each Opening
60,000
100 square inches
75,000
100 square inches
90,000
100 square inches
105,000
105 square inches
120,000
120 square inches
IMPORTANT: Do not take air from
an attic space that is equipped with
power ventilation.
The confined space must communicate with the outdoors in accordance
with Methods 1 or 2. The minimum
dimension of air openings shall not
be less than 3 inches. Where ducts
are used, they shall be of the same
cross-sectional area as the free area
of the openings to which they connect.
Method 1
Two permanent openings, one located within 12 inches of the top and
one located within 12 inches of the
bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that
freely communicate with the outdoors.
INDOOR AIR OPENING DIMENSIONS
BTUH
Input
B. USING OUTDOOR AIR FOR
COMBUSTION
a. Where directly communicating
with the outdoors or where communicating to the outdoors
through vertical ducts as shown in
Figure 13, each opening shall
have a minimum free area of 1
square inch for each 4000 BTUH
of total appliance input rating in
the enclosure. See Table 3.
FIGURE 12
AIR FROM HEATED SPACE
TABLE 3
VERTICAL OUTDOOR AIR OPENING
DIMENSIONS
BTUH
Input
Free Area
Each Opening
Round Pipe
Size
60,000
15.00 square inches
5"
75,000
18.75 square inches
5"
90,000
22.50 square inches
6"
105,000
26.25 square inches
6"
120,000
30.00 square inches
7"
AO77501
17
b. Where communicating with outdoors through horizontal ducts,
each opening shall have a minimum
free area of 1 square inch for each
2000 BTUH of total input rating of
all equipment in the enclosure. See
Table 4 and Figure 14.
Combustion air openings must not be
restricted in any manner.
CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.
FIGURE 13
AIR FROM ATTIC/CRAWL SPACE
TABLE 4
HORIZONTAL OUTDOOR AIR
OPENING DIMENSIONS
BTUH
Input
Free Area
Each Opening
Round Pipe
Size
60,000
30.00 square inches
7"
75,000
37.50 square inches
7"
90,000
45.00 square inches
8"
105,000
52.50 square inches
9"
120,000
60.00 square inches
9"
Method 2
One permanent opening, located
within 12 inches of the top of the
enclosure, shall be permitted where
the equipment has clearances of at
least 1 inch from the sides and back
and 6 inches from the front of the
appliance. The opening shall directly
communicate with the outdoors or
communicate through a vertical or
horizontal duct to the outdoors or
spaces (crawl or attic) that freely
communicate with the outdoors, and
shall have a minimum free area of:
a. One square inch for each 3000
BTUH of the total input rating of
all equipment located in the
enclosure (see Table 5), and
AO77601
FIGURE 14
OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET
b. Not less than the sum of the
areas of all vent connectors in the
confined space.
If the unit is installed where there is
an exhaust fan, sufficient ventilation
must be provided to prevent the
exhaust fan from creating a negative
pressure.
TABLE 5
VERTICAL OR HORIZONTAL
OUTDOOR AIR OPENING DIMENSIONS
18
BTUH
Input
Free Area
Each Opening
Round Pipe
Size
60,000
20.00 square inches
6"
75,000
25.00 square inches
6"
90,000
30.00 square inches
7"
105,000
35.00 square inches
7"
120,000
40.00 square inches
8"
AO77701
INSTALLATION GUIDELINES
IMPORTANT: When installed as a nondirect furnace, only vertical terminations
are allowed. Do not use horizontal terminations when the furnace is installed
with a non-direct vent.
All exhaust vent piping must be installed
in compliance with Part 7, Venting of
Equipment, of the latest edition of the
National Fuel Gas Code NFPA 54/ANSI
A223.1, or CAN/CGA-B149.1 and .2,
local codes or ordinances and these
instructions.
VENTING GUIDELINES - Non-Direct
Vent
1. IMPORTANT: Do not common vent
with any other appliance. Do not
install in the same chase or chimney
with a metal or high temperature
plastic pipe from another gas or fuelburning appliance unless the
required minimum clearances to
combustibles are maintained
between the PVC pipe and other
pipes.
2. Use only medium or long radius
sweep elbows.
NOTE: For upflow and downflow
installations, extend the exhaust
pipe a minimum of 18" vertically
above the furnace cabinet before
turning the vent.
3. Vertical vent piping is preferred.
8. All piping through the roof is 2".
When using 3" pipe, reduce to
2" within 18" of the inside of
the roof.
6. All piping between the furnace and
the roof penetration is 2" or 3" as
specified in Table 6. Table 6 lists
the maximum allowable exhaust
vent pipe length for the number of
elbows used, based on the furnace
size.
9. Vertical through-the-roof installations do not require any special
vent termination. Use 2" PVC
pipe extending a minimum of
12 inches above the anticipated level of snow accumulation.
IMPORTANT: Use Only standard vertical terminations when installing the
modulating furnace as a non-direct
vent appliance.
➤ TABLE 6
NON-DIRECT VENT APPLICATIONS
MAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE
UPFLOW FURNACES
FURNACE PIPE
INPUT
SIZE
TERMINATION
(VERTICAL VENT
TERMINATIONS
ONLY)
NUMBER OF ELBOWS
45° OR 90°
MEDIUM / LONG RADIUS ONLY
1-2
3-4
5-6
2"
STANDARD
40'
35'
30'
3"
STANDARD
120'
120'
120'
2"
STANDARD
20'
15'
10'
3"
STANDARD
120'
120'
120'
90,000
3"
STANDARD
110'
105'
95'
105,000
3"
STANDARD
110'
105'
95'
120,000
3"
STANDARD
45'
35'
30'
60,000
75,000
4. Install all horizontal piping as follows:
• Slope horizontal vent piping upward
a minimum of 1/4" per foot of run so
that condensate drains toward the
furnace.
7. The minimum vent length is 5
feet.
Rubatex/Armaflex insulation. For
horizontal runs where water may
collect and freeze, wrap the vent
pipe with self-regulating, 3 or 5
Watt heat tape. The heat tape
must be U.L. listed and installed
per the manufacturer’s instructions.
• Support horizontal vent piping at
least every four feet. No sags or
dips are permitted.
DOWNFLOW/HORIZONTAL FURNACES
2"
STANDARD
30'
25'
20'
3"
STANDARD
120'
120'
120'
2"
STANDARD
20'
15'
10'
3"
STANDARD
120'
120'
120'
90,000
3"
STANDARD
90'
80'
75'
105,000
3"
STANDARD
45'
40'
35'
120,000
3"
STANDARD
40'
35'
30'
60,000
5. Insulate all vent runs through unconditioned spaces where below-freezing temperatures are expected, with
1" thick medium density, foil faced
fiber glass or equivalent
75,000
19
DIRECT VENT PIPE INSTALLATION
!
WARNING
READ AND FOLLOW ALL
INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY
VENT THIS FURNACE CAN
CAUSE CARBON MONOXIDE
POISONING OR AN EXPLOSION
OR FIRE, RESULTING IN PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
Direct vent installations require a dedicated combustion air and venting system. All air for combustion is taken
from outside and all combustion products are discharged to the outdoors.
Therefore, no ventilation or combustion air openings are required.
➤ TABLE 7
DIRECT VENT APPLICATIONS
MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE
AND INTAKE PIPE
UPFLOW FURNACES
FURNACE PIPE
INPUT
SIZE
2"
60,000
3"
INSTALLATION
GUIDELINES
All exhaust piping must be installed in
compliance with Part 7, “Venting of
Equipment,” of the latest edition of the
National Fuel Gas Code NPFA 54, 90A
and 90B ANSI Z223.1-, local codes or
ordinances and these instructions.
1. IMPORTANT: Do not common
vent with any other appliance. Do
not install in the same chase or
chimney with a metal or high temperature plastic pipe from another
gas or fuel-burning appliance
unless the required minimum
clearances to combustibles are
maintained between the PVC pipe
and other pipes.
2. Use only medium or long radius
sweep elbows.
2"
75,000
90,000
105,000
120,000
NOTE: For upflow and downflow
installations, extend the combustion air exhaust pipe a minimum
of 18" vertically above the furnace
cabinet before turning the vent.
3. Vertical piping is preferred.
3"
3"
2"
60,000
3"
2"
75,000
• Support horizontal vent piping at
least every four feet. No sags or
dips are permitted.
20
3"
STANDARD
RXGY-D02
CONCENTRIC
RXGY-E03
ALTERNATE
RXGY-D02
STANDARD
RXGY-D03
CONCENTRIC
RXGY-E03
ALTERNATE
NUMBER OF ELBOWS
221⁄2°, 45° OR 90°
MEDIUM / LONG
RADIUS ONLY
1-2 3-4 5-6
40'
35'
30'
30'
25'
20'
120'
120'
120'
RXGY-D03
110'
105'
100'
STANDARD
RXGY-D02
20'
15'
10'
STANDARD
RXGY-D03
CONCENTRIC
RXGY-E03
120'
120'
120'
ALTERNATE
RXGY-D03
100'
95'
85'
STANDARD
RXGY-D03
CONCENTRIC
RXGY-E03
110'
105'
95'
ALTERNATE
RXGY-D03
50'
40'
35'
STANDARD
RXGY-D03
CONCENTRIC
RXGY-E03
110'
105'
95'
ALTERNATE
RXGY-D03
50'
40'
35'
STANDARD
RXGY-D03
CONCENTRIC
RXGY-E03
45'
35'
30'
ALTERNATE
RXGY-D03
45'
35'
30'
ALTERNATE
RXGY-D04
105'
95'
90
DOWNFLOW/HORIZONTAL FURNACES
4. Install all horizontal piping as follows:
• Slope horizontal vent piping
upward a minimum of 1/4" per foot
of run so that condensate drains
toward the furnace.
3"
TERMINATION
VENT
TERMINATION KIT
RECOMMENDED
3"
90,000
3"
105,000
3"
120,000
3"
STANDARD
RXGY-D02
30'
25'
20'
CONCENTRIC
RXGY-E03
30’
25’
20’
STANDARD
RXGY-D03
120'
120'
120'
CONCENTRIC
RXGY-E03
120’
120’
120’
STANDARD
RXGY-D02
20'
15'
10'
CONCENTRIC
RXGY-E03
20’
15’
10’
STANDARD
RXGY-D03
120'
120'
120'
CONCENTRIC
RXGY-E03
120'
120'
120'
STANDARD
RXGY-D03
70'
60'
55'
CONCENTRIC
RXGY-E03
70’
60’
55’
STANDARD
RXGY-D03
45'
40'
35'
CONCENTRIC
RXGY-E03
45'
40'
35'
STANDARD
RXGY-D03
40'
35'
30'
CONCENTRIC
RXGY-E03
40’
35’
30’
FIGURE 15
STANDARD VERTICAL DIRECT VENTING
UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)
5
DETAIL A
1
12”
5
EXHAUST
TERMINATION
2
3
NOTES:
THE COMBUSTION AIR PIPE
MUST TERMINATE IN THE
SAME PRESSURE ZONE AS
THE EXHAUST PIPE.
INCREASE THE 12-IN. MINIMUM
TO KEEP TERMINAL OPENING ABOVE
ANTICIPATED LEVEL OF SNOW ACCUMULATION WHERE APPLICABLE.
WHEN 3-IN. DIAM. PIPE IS USED,
REDUCE TO 2-IN. DIAMETER BEFORE
PENETRATING ROOF. A MAXIMUM OF
18 IN. OF 2-IN. PIPE MAY BE USED
BEFORE PASSING THROUGH ROOF.
SUPPORT VERTICAL PIPE EVERY 6
FEET.
EXHAUST TERMINATION - TERMINATE
THE LAST 12 INCHES WITH 2” PVC
PIPE ON 90,000 AND 120,000 BTUH
MODELS. REDUCE AND TERMINATE
THE LAST 12 INCHES WITH 11/2” PVC
PIPE ON 45,000 THROUGH 75,000
BTUH MODELS.
SEE DETAIL A.
1
5
4
2
3
5
4
5
5. Insulate all vent runs through
unconditioned spaces where
below-freezing temperatures are
expected with 1" thick medium
density, foil faced fiber glass or
equivalent Rubatex/Armaflex insulation. For horizontal runs where
water may collect, wrap the vent
pipe with self-regulating, 3 or 5
Watt heat tape. The heat tape
must be U.L. listed and installed
per the manufacturer’s instructions.
6. All piping between the furnace and
the roof or outside wall penetration
is 2" or 3" as specified in Table 7.
Table 7 lists the maximum allowable length for the exhaust vent
pipe and intake air pipe for the
number of elbows used, based on
the type of termination and furnace size.
7. The minimum vent length is 5
feet.
ST-A0407-00
VERTICAL TERMINATIONS
STANDARD VERTICAL TERMINATIONS (See Figure 15)
Combustion Air Piping: Use two medium-radius sweep elbows to keep the
inlet downward and prevent the entry of
rain. The inlet opening of the combustion air termination must be a
minimum of 12" above the anticipated level of snow accumulation.
Exhaust Vent Piping: The exhaust vent
must terminate at least 12 inches
above the combustion air termination
inlet. The 2" vent pipe used to penetrate the roof must be reduced to 1 1/2"
PVC for the last 12" for the 60,000 and
75,000 BTUH furnace models. No
reduction of the 2" pipe is necessary for
the 90,000 through 120,000 BTUH
models. The maximum length of the
exposed vent pipe above the roof is
30".
8. All piping through the roof or outside wall is 2". When using 3"
pipe, reduce to 2" within 18" of
the inside of the roof or outside
wall (except 120,000 BTUH
model using the RXGY-D04
Horizontal Vent Kit).
9. Terminate the vent using one of
the following termination options.
21
CONCENTRIC TERMINATIONS
CONCENTRIC VENT KIT
NO. RXGY-E03 (SEE FIGURE 16)
This kit is for vertical and horizontal
intake air/vent runs. One
5-in. diameter hole is required for
installation. See Figure 13 for the general layout. Complete installation
instructions are included with the kit.
FIGURE 16
CONCENTRIC VENT KIT NO. RXGY-E03
(DIRECT VENT INSTALLATIONS)
ITEM No.
VERTICAL INSTALLATION
MAINTAIN 12 IN.
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24 IN. ABOVE ROOF.
DESCRIPTION
1
2.5" PVC PIPE SCHEDULE 40 -- 37.125" LONG
2
4" PVC PIPE SCHEDULE 40 -- 24" LONG
3
3" x 3" x 4" SPECIAL CONCENTRIC FITTING
4
3" x 45° STREET ELBOW (FIELD SUPPLIED)
5
PVC RAINCAP
HORIZONTAL INSTALLATION
FIELD-SUPPLIED
STRAP
1" MAXIMUM
NOTE: AIR INTAKE NOT
ORIENTATION SENSITIVE.
22
HORIZONTAL TERMINATIONS
STANDARD HORIZONTAL TERMINATIONS (SEE FIGURE 17)
NOTE: All furnaces with horizontal air
intakes (except those using horizontal
concentric vent kit RXGY-E03) must
have a drain tee assembly and trap
installed in the combustion air pipe as
close to the furnace as possible. This is
to drain any water that may enter the
combustion air pipe to prevent it from
entering the furnace vestibule area.
These parts are included in horizontal
vent kits RXGY-D02, RXGY-D03 and
RXGY-D04.
NOTE: The combustion air and exhaust
terminations must be at least 12 inches
above grade or anticipated snow levels.
Use alternate horizontal terminations
when termination locations are limited
and higher snow levels are anticipated.
NOTE: Ensure the location of the combustion air inlet with respect to the
exhaust vent terminal complies with
Figure 17, detail C.
Combustion Air Piping: Use a 2" PVC
coupling with a wind deflector vane (provided) installed as follows:
1. Install a 2" coupling to the combustion air pipe at the outside wall to
prevent the termination from being
pushed inward.
2. Cut a 2 1/4" length of 2" PVC pipe
and connect this to the coupling.
3. Connect another 2" coupling to the
end of the 2 1/4" length of pipe.
Terminate this outer coupling 4
inches from the wall.
4. Attach the vane in the final 2" coupling in the vertical position with
PVC cement.
IMPORTANT: To insure proper furnace operation, install the vane in the
vertical position as shown in Figure
17, Detail B. Failure to install the vane
properly can result in nuisance tripping of the pressure switch.
FIGURE 17
1
STANDARD HORIZONTAL DIRECT VENTING
UPFLOW MODEL SHOWN
(TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)
2
Exhaust Vent Piping:
60,000 and 75,000 BTUH models:
Install a 2" to 1 1/2" reducer coupling at the outside wall to prevent
the termination from being pushed
inward. Reduce the 2" vent pipe
used to penetrate the wall to 1 1/2"
PVC for the last 12" of the run.
Terminate the 1 1/2" PVC exhaust
vent at least 12 inches from the outside wall.
90,000 through 120,000 BTUH
models: Install a 2" coupling at the
outside wall to prevent the termination from being pushed inward. No
reduction of the 2" pipe used to
penetrate the wall is necessary.
Terminate the 2" PVC exhaust vent
at least 12 inches from the outside
wall.
3
5
NOTES:
SUPPORT HORIZONTAL
PIPE EVERY FOUR FEET.
WHEN 3 IN. PIPE IS USED REDUCE
TO 2 IN. BEFORE PENETRATING
OUTSIDE WALL.
18 IN. MAXIMUM. 2 IN. DIAMETER
PIPE MAY BE USED INSIDE THE
WALL.
DETAIL “A” - EXHAUST TERMINATION
TERMINATE THE LAST 12 INCHES
WITH 2” PVC PIPE ON 90,000 AND
120,000 BTUH MODELS. REDUCE
AND TERMINATE THE LAST 12 INCHES WITH 11/2” PVC PIPE ON 45,000
THROUGH 75,000 BTUH MODELS.
INCREASE THE 12 IN. MINIMUM
ABOVE GRADE TO KEEP TERMINAL
OPENINGS ABOVE ANTICIPATED
LEVEL OF SNOW ACCUMULATION
WHERE APPLICABLE.
DETAIL “B”, INSTALL WIND DEFLECTOR VANE IN 2 IN. PVC COUPLING IN
VERTACLE POSITION USING PVC
SOLVENT.
THE COMBUSTION AIR TERMINATION MUST BE IN THE SAME PRESSURE ZONE AS THE EXHAUST TERMINATION.
4
1
2
DETAIL A
12”
EXHAUST
TERMINATION
3
4
DETAIL C
EXHAUST/INTAKE RELATIONSHIP
6
DETAIL B
COMBUSTION AIR TERMINATION
5
6
ST-A0407-00
23
ALTERNATE HORIZONTAL TERMINATIONS (See Figure 18)
FIGURE 18
ALTERNATE HORIZONTAL DIRECT VENT TERMINATION
EXHAUST VENT
21/2" PVC FOR MODELS WITH 120,000 BTUH INPUT
(KIT NO. RXGY-D04)
2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000
BTUH. REDUCE TO 11/2" FOR MODELS WITH INPUTS OF
60,000 AND 75,000 BTUH. ELBOWS AND RISERS ARE 2" PVC.
NOTE: This method is NOT
ALLOWED on downflow furnaces.
NOTE: The combustion air and
exhaust terminations must be at least
12 inches above grade or anticipated
snow levels. Alternate horizontal terminations allow the combustion air
and exhaust terminations to be raised
a maximum of 60 inches above the
wall penetrations to maintain the
required clearance.
3" MAX.
NOTE: 3-1/2"
MAX. WHEN
D04 KIT IS
USED.
DETAIL A
60" MAX.
M
O
FR
PIPE
SUPPORT
STRAP
DETAIL C
EXHAUST/INTAKE RELATIONSHIP
L
AL
W
NOTE: Ensure the location of the
combustion air inlet with respect to
the exhaust vent terminal complies
with Figure 18.
SEE DETAIL A
"
12
NOTE: If combustion air vent pipe is
extended more than 24 inches, insulate the vent pipe between the two
outside 90° elbows with closed cell
insulation such as rubatex, armaflex
or equivalent.
INTAKE VENT
21/2" PVC FOR MODELS WITH
120,000 BTUH INPUT.
2" PVC ELBOWS AND RISER
MODELS WITH INPUTS OF 75,000
THRU 120,000 BTUH.
USE KIT NO. RXGY-D02 WHEN 2" PIPE
IS USED BETWEEN FURNACE AND OUTSIDE WALL. USE KIT NO. RXGY-D03
WHEN 3" PIPE IS USED.
EXHAUST VENT FOR
MODELS WITH INPUT OF
60,000 AND 75,000 BTU
Combustion Air Piping: Use a 2" PVC
elbow with a wind deflector vane (provided) installed as follows:
1. Install a 2" elbow to the combustion
air pipe at the outside wall to prevent
the termination from being pushed
inward.
2. Cut an adequate length of 2" PVC
pipe as needed to clear the anticipated snow level and connect this to
the elbow.
3. Connect another 2" elbow to the
end of the pipe such that the inlet is
facing away from the wall. This outer
coupling must terminate 4 inches
from the wall.
4. Attach the vane in the final 2" elbow
in the vertical position with PVC
solvent.
IMPORTANT: To insure proper furnace operation, the supplied vane
must be installed in the vertical position as shown in Figure 18, Detail A.
24
I339
Exhaust Vent Piping:
Exhaust Vent Termination:
1. Install a 2" elbow to the exhaust vent
pipe at the outside wall to prevent the
termination from being pushed
inward.
60,000 and 75,000 BTUH models:
Reduce the 2" vent pipe used to
penetrate the wall and extend the
terminations to 1 1/2" PVC for the
last 12" of the run. Install a 2" to 1
1/2" reducer bushing in the last 2"
elbow. Connect a length of 1 1/2"
PVC pipe such that the exhaust vent
terminates at least 12 inches from
the outside wall. See Figure 18,
Detail A.
90,000 through 120,000 BTUH models: No reduction of the 2" pipe used
to penetrate the wall is necessary.
Terminate the 2" PVC exhaust vent
at least 12 inches from the outside
wall.
120,000 BTUH model with the
RXGY-D04 Horizontal Vent Kit:
Venting and terminations install the
same as above except the 2" pipe
and connectors are replaced with 2
1/2" pipe and connectors.
2. Cut an adequate length of 2" PVC
pipe as needed to insure proper location of the exhaust vent termination
with respect to the combustion air
inlet and connect this to the elbow.
3. Connect another 2" elbow to the end
of the pipe such that the inlet is facing away from the wall.
LOCATION REQUIREMENTS
HORIZONTAL DIRECT VENTS
!
CAUTION
THE COMBUSTION PRODUCTS
AND MOISTURE IN THE FLUE
GASES WILL CONDENSE AS
THEY LEAVE THE TERMINATION. THE CONDENSATE CAN
FREEZE ON THE EXTERIOR
WALL, UNDER THE EAVES AND
ON SURROUNDING OBJECTS.
SOME DISCOLORATION TO THE
EXTERIOR OF THE BUILDING IS
TO BE EXPECTED. HOWEVER,
IMPROPER LOCATION OR
INSTALLATION CAN RESULT IN
STRUCTURAL OR EXTERIOR
FINISH DAMAGE TO THE BUILDING AND MAY RECIRCULATE
PRODUCTS OF COMBUSTION
INTO THE COMBUSTION AIR
TERMINAL AND FREEZE.
NOTE: In Canada vent terminations
must be in accordance with the current
CSA-B149 Gas Installation Code and/or
local codes.
In addition to the minimum clearances
listed above, the vent location should
be governed by the following guidelines.
1. Do not terminate under any kind of
patio or deck. If running the vent
under a deck, insulate it to insure
no condensate freezes and blocks
the pipe.
2. Do not terminate behind any area
that may allow the flue products to
become stagnant and recirculate.
3. Do not locate on the side of a
building with prevailing winter
winds. This will help prevent moisture from freezing on walls and
overhangs (under eaves).
4. Do not extend vent directly
through brick or masonry sur-
faces. Use a rust-resistant sheet
metal or plastic backing plate
behind vent. See Figure 16.
5. Do not locate too close to shrubs
as condensate may stunt or
kill them.
6. Minimum vertical clearances of 1
foot are recommended for overhangs up to 1 foot horizontal.
The vertical clearance should be
increased equally for each additional increase in horizontal overhang to a maximum vertical
clearance of 6 feet.
7. Caulk all cracks, seams and
joints within 6 feet horizontally
as well as 6 feet above and
below vent. See Figure 16.
FIGURE 19
MOISTURE ZONES
The vent must be installed with the following minimum clearances. See
Figures 19 and 20.
1. Locate the bottom of the vent terminal and the air inlet at least 12
inches above grade. Increase the
12-in. minimum to keep the terminal openings above the level of
snow accumulation, where applicable.
2. Do not terminate the vent over public walkways or over an area where
condensate or vapor could create a
nuisance or hazard.
3. Locate the vent terminal at least
one foot from any opening through
which flue gases could enter a
building.
2 FT. SQ. SHEET METAL PLATE ON BRICK OR
MASONRY SURFACE RECOMMENDED, BUT
NOT REQUIRED BY CODE.
4. Locate the vent terminal at least 3
feet above any forced air inlet
located within 10 feet, except the
combustion air inlet of a direct vent
appliance.
5. Allow the vent terminal minimum
horizontal clearance of 4 feet from
electric meters, gas meters, regulators and relief equipment.
6. Locate the furnace combustion air
inlet a sufficient distance from the
vent of any other gas or fuel burning appliance or electric clothes
dryer to prevent recirculation of the
flue gases into the furnace combustion air inlet. The only exception
to this requirement is the case of
multiventing two or more furnaces,
which is covered in the section on
multiventing in these instructions.
25
Canadian Installations
US Installations
26
US Installations
Natural Gas and Propane Installation Code
National Fuel Gas Code
Canadian Installations
FIGURE 20
DIRECT VENT TERMINAL CLEARANCES
FIGURE 21
FIGURE 22
TWO FURNACE VENTING THROUGH ROOF
TWO FURNACE VENTING THROUGH WALL
TWO-PIPE VENTING
TWO-PIPE VENTING
EXHAUST VENT
MODELS 06-07
TO BE REDUCED TO
1-1/2” PVC LAST 12”.
3” MININUM
24” MAXIMUM
3” MININUM
24” MAXIMUM
CONCENTRIC VENTING
CONCENTRIC VENTING
8” MININUM
24” MAXIMUM
8"
MINIMUM 12" ABOVE AVERAGE
SNOW ACCUMULATION. MAXIMUM
OF 24 IN. ABOVE ROOF.
SEE CONCENTRIC
VENT SECTION
ON PAGE 20
FOR MORE
INFORMATION.
6' MINIMUM
10' RECOMMENDED
MINIMUM 12"
ABOVE GRADE
MAXIMUM 1"
DISTANCE
FROM WALL
8"
8” MININUM
24” MAXIMUM
8.
Painted surfaces must be sound
and in good condition with no
cracking, peeling, etc. Painted
surfaces will require maintenance.
9. Do not expose 3" x 2" reducer/
bushing to outdoor ambient temperatures.
MULTIVENTING
IF VENTING TWO OR MORE FURNACES NEAR EACH OTHER IS
REQUIRED, EACH FURNACE
MUST BE INDIVIDUALLY VENTED
– NO COMMON VENTING IS PERMITTED. See Figures 18 and 19 for
positioning of the terminations. When
more than two furnaces are to be
vented, there must be at least 4 feet
between the first two furnaces and
the third, etc.
SEE CONCENTRIC VENT SECTION
ON PAGE 20 FOR MORE INFORMATION.
CONNECTING TO
FURNACE
IMPORTANT: Clean and deburr all
pipe cuts. The shavings must not be
allowed to block the exhaust, inlet or
condensate drain pipes.
IMPORTANT: When indoor combustion air is used, the inlet air opening
at the furnace must be protected
from accidental blockage. On downflow models, install a double elbow in
the top inlet air opening. See Figure
25.
27
UPFLOW MODELS
The exhaust air pipe connection is a 2in. female PVC pipe fitting extending
through the left side of the furnace top
plate. See Figure 23. This opening has a
protective cap which should be removed
just prior to installing the exhaust pipe.
When 2-in. pipe is used, connect it
directly to this fitting. When 3-in. pipe is
used, connect a 2 to 3-in. coupling to
this fitting with a short piece of 2-in. PVC
pipe.
The inlet combustion air connection
is at the right side of the top plate.
An alternate combustion inlet air connection may be made on the right side of
the jacket. The alternate connection
opening has a plastic cap. A combustion
inlet air connection fitting is supplied with
the furnace and it must be installed in
the furnace by screwing it into the opening. Make sure the rubber “O-ring” supplied with the furnace is used with this
fitting. See Figures 23 and 24.
IMPORTANT: When using indoor combustion air, the furnace air opening must
be protected from accidental blockage.
Install a 2-inch 90° elbow pointing downward on the side or a double elbow
pointing downward in the top opening.
See Figure 24.
FIGURE 23
UPFLOW MODELS -- COMBUSTION AIR AND VENT PIPE CONNECTION
“O” RING
TOP PLATE
VENT CAP/PLUG
EXHAUST AIR PIPE
COMBUSTION
AIR ADAPTER
NOTE:
WHEN COMBUSTION AIR INLET IS IN
OPTIONAL POSITION SWAP LOCATION
OF INLET AIR ADAPTER AND “O” RING
WITH PLUG.
PLUG OPT. COMBUSTION
AIR INLET POSITION
INDUCED DRAFT
BLOWER
EXHAUST TRANSITION
CONNECTOR
CONDENSATE TRAP
I515
FIGURE 24
UPFLOW MODELS -- COMBUSTION AIR FITTING
ATTACH DOUBLE ELBOW TO TOP INLET AIR
OPENING OR 90° ELBOW TO SIDE INLET AIR
OPENING TO PREVENT ACCIDENTAL BLOCKAGE
OF INTAKE OPENING. PLUG OPENING NOT USED.
➤DOWNFLOW/HORIZONTAL
MODELS
2” PVC DOUBLE
ELBOW
TOP INLET
AIR OPTION
EXHAUST
NOTE: Combustion air inlet and exhaust
outlet air pipes are reversed for downflow from that of upflow.
The exhaust pipe connection is a 2-in.
PVC pipe fitting extending through the
right side of the furnace top cover. This
opening has a protective cap which
should be removed just prior to installing
the exhaust pipe. When 2-in. pipe is
used, connect it directly to this fitting.
When 3-in. pipe is used, connect with a
2- to 3-in. coupling directly to the 2-in.
pipe.
The combustion inlet air connection is a
2-in. extruded hole on the left side of the
top plate. When a 2-in. pipe is used,
attach a 2-in. PVC coupling over this
hole with RTV sealant and also add two
sheet metal screws through the coupling
into the extrusion to secure it in place,
and add the required piping. When 3-in.
pipe is required, use a 2- to 3-in. coupling and add the required piping. See
Figure 25
IMPORTANT: Always pre-drill holes
before securing with screws. Using selftapping screws without first pre-drilling
causes the PVC fitting to crack.
28
2” PVC ELBOW
SIDE INLET AIR
OPTION
UPFLOW
1337
➤ FIGURE 25
DOWNFLOW/HORIZONTAL MODELS -- COMBUSTION AIR AND VENT PIPE CONNECTION
2” PVC DOUBLE
ELBOW
ATTACH DOUBLE ELBOW TO INTAKE AIR COLLAR AND
SECURE WITH TWO SHEET METAL SCREWS TO PREVENT
ACCIDENTAL BLOCKAGE OF INTAKE AIR OPENING.
INLET AIR
EXHAUST
CONDENSATE DRAIN/OPTIONAL NEUTRALIZER
GENERAL INFORMATION
!
CAUTION
FIGURE 26
UPFLOW CONDENSATE DRAIN
DO NOT RUN DRAIN OUTDOORS.
FREEZING OF CONDENSATE CAN
CAUSE PROPERTY DAMAGE.
IMPORTANT: Do not connect into a common drain line with an air conditioner
evaporator coil drain located below the
furnace. A blocked or restricted drain line
can result in overflow of the coil pan and
negate the furnace blocked-drain shutoff
control.
➤ IMPORTANT: If installing the unit over
a finished ceiling or living area, be certain
to install an auxiliary condensate drain
pan under the entire unit extending out
under the condensate tee. With the minimum 51⁄2" riser for upflow models
or 13⁄4" for downflow models installed
above the tee, a blocked drain will result
in overflow from the riser. if the furnace is
installed in an attic, crawlspace or other
area where freezing temperatures may
occur, the furnace drain can freeze while
shut off for long periods of time.
If required by local codes, install a condensate neutralizer cartridge in the drain
line. Install cartridge in horizontal position
only. Also install an overflow line if routing
to a floor drain (see Figure 23). If available, install a condensate pump that is
resistant to acidic water. Pumps are available from your local distributor. If pump
used is not resistant to acidic water, a
condensate neutralizer must be used
ahead of the pump. The condensate
pump must have an auxiliary safety
switch to prevent operation of the furnace
and resulting overflow of condensate in
the event of pump failure. The safety
switch must be wired through the “R” circuit only (low voltage) to provide operation
in either heating or cooling modes.
UPFLOW MODELS
The condensate drain trap is located in
the blower compartment on the left- hand
side of the jacket. A short piece of 1⁄2-in.
PVC pipe and a 1⁄2-in. tee are provided.
Connect the 1⁄2-in. pipe to the elbow on
the trap and the tee to this pipe so that
the open end is upward. Run a drain tube
from the bottom of the tee to a floor drain
or condensate pump.
IMPORTANT: If installing the unit over a
finished ceiling or living area, be certain
to install an auxiliary condensate drain
pan under the entire unit extending out
under the condensate tee.
IMPORTANT: There are two options
when choosing a height for the condensate riser:
NOTE:
SEE UPFLOW MODEL
NOTES FOR PIPE
HEIGHT
CONDENSATE TRAP
DRAIN LINE
NEUTRALIZER CARTRIDGE
(OPTIONAL)
OVERFLOW LINE
(REQUIRED ONLY WHEN
OPTIONAL NEUTRALIZER
CARTRIDGE IS USED.)
TO FLOOR DRAIN OR CONDENSATE PUMP
AO51601
➤ FIGURE 27
DOWNFLOW CONNECTION
NOTE: SEE DOWNFLOW
MODEL NOTES
OVERFLOW LINE
(REQUIRED ONLY WHEN
CARTRIDGE IS USED.)
CONDENSATE TRAP
DRAIN LINE
NEUTRALIZER CARTRIDGE
(OPTIONAL)
TO FLOOR DRAIN OR CONDENSATE PUMP
A085001
29
CONDENSATE OVERFLOW: With a
51⁄2 inch riser installed above the tee, a
blocked drain will result in overflow
from the riser.
FURNACE SHUTDOWN: To cause the
furnace to shut down when a blocked
drain is present, install a riser which is
a minimum of 1013⁄16”. If the furnace is
installed in an attic, crawlspace or
other area where freezing temperatures may occur, the furnace drain
can freeze while shut off for long periods of time.
Use a solvent cement that is compatible with PVC material. Cut the drain
hoses to the appropriate length and
connect to the trap with hose clamps.
Tighten the clamps with pliers and
check for leaks after attaching.
DOWNFLOW MODELS
IMPORTANT: There are two options
when choosing a height for the condensate riser:
CONDENSATE OVERFLOW: With a
13⁄4 inch riser installed above the tee, a
blocked drain will result in overflow
from the riser.
FURNACE SHUTDOWN: To cause the
furnace to shut down when a blocked
drain is present, install a riser which is
a minimum of 51⁄2”. If the furnace is
installed in an attic, crawlspace or
other area where freezing temperatures may occur, the furnace drain
can freeze while shut off for long periods of time.
Use a solvent cement that is compatible with PVC material.
➤ DOWNFLOW MODELS
To convert to left side drainage, first
remove the drainage hoses from the
trap. Remove the trap from its mounting bracket, rotate it 180°, and mount
in place with the drainage elbow pointing to the left. Reattach the drain
hoses. Remove the plastic drainage
knockout from the left side. See
Figure 29.
IMPORTANT: When changing to the
left side, interchange the rubber grommet on the right side with the hole
plug on the left side. The hole plug
must be in place to assure that the
control compartment is sealed.
A length of 1⁄2" PVC pipe is provided
for left hand drainage. Glue one end
of the pipe to the elbow in the trap.
Cut the pipe so that it extends through
the left cabinet side one inch. Connect
the 1⁄2" tee to the pipe with a 13⁄4" riser
and drain tube as listed above. Use
the plastic plug from the left side
drainage knockout to seal the right
side drainage knockout.
IMPORTANT: Do not connect into a
common drain line with an air conditioner evaporator coil drain located
above the furnace. A blocked or
restricted drain line can result in overflow of the coil pan and negate the
furnace blocked drain shutoff control.
FILLING THE TRAP
FILL THE TRAP ASSEMBLY WITH
WATER BEFORE OPERATING THE
FURNACE. Do this by removing the
drain hose from the trap or from the
connection to the secondary coil.
Pour about a cup of water into the
vent trap. Any excess water flows into
the house drain when the trap is full.
FIGURE 28
UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION
51/2” MINIMUM
HEIGHT OPEN
END
REVERSING THE TRAP
UPFLOW MODELS
The trap may be moved to the right
side for right side drainage. Open the
knockout for the drain on the right side
of the cabinet. Remove the bracket
holding the trap from the left side.
Seal the left side drain hole with a
plug provided in the cloth bag with the
furnace. Position the mounting bracket
and trap so that the drain elbow is
centered in the hole on the right. See
Figure 28.
Drill two holes in the cabinet to mount
the bracket. Mount the trap and bracket to the right side with the drain
elbow pointing through the knockout.
Connect the 1⁄2" pipe and tee as noted
above. Route the drain hoses behind
the top of the electric box, cut to the
appropriate length, and connect to the
trap with hose clamps.
IMPORTANT: Do not connect into a
common drain line with an air conditioner evaporator coil drain located
above the furnace. A blocked or
restricted drain line can result in overflow of the coil pan and negate the
furnace blocked drain shutoff control.
A051701
➤ FIGURE 29
DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION
A086301
30
CONDENSATE DRAIN
FOR HORIZONTAL
INSTALLATION
-GGD furnace in the horizontal configuration, a special kit must be used to
convert the furnace for horizontal
installation. The necessary kits are listed here.
HORIZONTAL
FURNACE
CONVERSION
MODEL
KIT
(-)GGD-06
RXGY-G01
(-)GGD-07
RXGY-G02
(-)GGD-09
RXGY-G03
(-)GGD-10
RXGY-G04
(-)GGD-12
RXGY-G05
Refer to Figure 31 for Steps 1-5.
1. This unit is shipped factory ready
for downflow installation. The condensate trap assembly and drain
hoses require conversion for horizontal installation.
Remove the existing condensate
trap with the unit in the upright
position.
2. Remove the burner compartment
door from the unit.
3. Remove the two screws from the
right side of the furnace jacket
which support the trap mounting
bracket ➁. Remove the two plastic plugs on either side of the trap
outlet hole and discard.
4. Remove the (L-shaped) clear,
ribbed vinyl drain tube (3) from
the top of the existing trap (1).
Do not disconnect the short end
from the furnace collector box.
5. Remove the clear ribbed drain
tube (4) from the existing trap (3)
and the exhaust transition (5).
Discard this tube. Retain the
clamps for future use. Additional
clamps are provided in the parts
bag if any clamps are damaged
during conversion process.
NOTE: The following steps should
take place with the furnace in the
horizontal position.
Refer to Figure 32 for Steps 6-11.
6. Locate the parts bag in the burner
compartment. Install two plastic
plugs (6) in the side of the jacket
from bottom side up.
7. Fill the replacement trap assembly (7) with 1/2 cup of water.
8. Attach the self-adhesive gasket
(8) onto the trap assembly so that
the gasket holes on the gasket
line up with the holes on the trap
assembly.
9. Remove plastic plugs from the
two screw holes to be used in the
horizontal position (see Figure
32). Insert the trap assembly with
gasket up through the existing
hole in the jacket and secure from
inside the jacket. Use two screws
provided. Screw down into the
two “ears” molded into either side
of the trap. Snug the trap assembly against the furnace jacket
compressing the gasket slightly to
eliminate any air leaks. Do not
overtighten!
10. Attach the black molded rubber
90° elbow (9) to the straight spout
on the trap top using a black
nylon clamp (10). Attach the other
end of the rubber elbow to the
spout (1) located on the exhaust
transition (5) using a black nylon
clamp
11. Attach the end of the ribbed tube
(3) to the 45° elbow molded into
the top of the trap assembly
using a black nylon clamp.
IMPORTANT: Tighten all clamp
connections with a pair of pliers
and check for leaks after conversion is complete.
12. Connect a 51⁄2 riser to the top of
the tee and run a drain tube from
the bottom of the tee to a floor
drain or condensate pump. Use
a solvent cement that is compatible with PVC material.
FIGURE 30
HORIZONTAL CONDENSATE DRAIN
31
32
HORIZONTAL POSITION: CONDENSATE TRAP INSTALLATION FOR HORIZONTAL
OPERATION
I534.DGN
FIGURE 32
UPRIGHT POSITION: REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP
CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO
HORIZONTAL INSTALLATION
FIGURE 31
ST-A0872-01
GAS SUPPLY AND PIPING
GAS SUPPLY
!
FIGURE 33
GAS PIPING -- UPFLOW INSTALLATION
WARNING
THIS FURNACE IS EQUIPPED
AT THE FACTORY FOR USE ON
NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A
SPECIAL KIT SUPPLIED BY THE
DISTRIBUTOR OR MANUFACTURER. MAILING ADDRESSES
ARE LISTED ON THE FURNACE
RATING PLATE, PARTS LIST
AND WARRANTY. FAILURE TO
USE THE PROPER CONVERSION KIT CAN CAUSE FIRE,
CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY
OR DEATH.
See the conversion kit index supplied with the furnace. This index
identifies the proper LP Gas
Conversion Kit required for each
particular furnace.
GROMMET
MAIN GAS VALVE
TOP VIEW OF GAS LINE AND VALVE
IN OPTIONAL POSITION
BURNERS
OPTIONAL GAS LINE
POSITION
4 TO 5 FEET
ABOVE FLOOR
REQ’D BY SOME
UTILITIES.
PLUG
(IN NORMAL
POSITION)
MANIFOLD
PRESSURE TAP
GROMMET
(IN NORMAL
POSITION)
IGNITER
MANIFOLD
DRIP LEG
STA0518-01
GAS VALVE
UNION
(TYPICAL INSTALLATION)
IMPORTANT: Do not run a flexible gas connector inside the unit.
➤ FIGURE 34
GAS PIPING -- HORIZONTAL INSTALLATION
MANUAL GAS VALVE
IMPORTANT: Any additions, changes
or conversions required for the furnace
to satisfactorily meet the application
should be made by a qualified installer,
service agency or the gas supplier,
using factory-specified or approved
parts.
GAS VALVE
DRIP LEG
IMPORTANT: Connect this furnace
only to gas supplied by a commercial
utility.
IMPORTANT: A U.L. recognized
fuel gas and CO detector(s) are recommended in all applications, and their
installation should be in accordance
with the manufacturer’s recommendations and/or local laws, rules, regulations or customs.
NOTE: WHEN GAS LINE IS IN
OPT. POSITION, SWAP LOCATION OF GROMMET AND
PLUG.
BURNERS
IGNITOR
MANIFOLD
A087401-01
MANIFOLD
PRESSURE TAP
➤ FIGURE 35
GAS PIPING -- DOWNFLOW INSTALLATION
GAS PIPING
Install the gas piping according to all
local codes and regulations of the utility company.
If possible, run a separate gas supply
line directly from the meter to the furnace. Consult the local gas company
for the location of the manual main
shut-off valve. The gas line and manual gas valve must be adequate in
size to prevent undue pressure drop
and never smaller than the pipe size
GROMMET
MAIN GAS VALVE
TOP VIEW OF GAS LINE AND VALVE
IN OPTIONAL POSITION
NOTE:
WHEN GAS LINE IS IN OPT.
POSITION, SWAP LOCATION
OF GROMMET AND PLUG.
4 TO 5 FT.
ABOVE
FLOOR
REQ’D BY
SOME
UTILITIES.
GAS VALVE
PLUG
(IN NORMAL
POSITION)
GROMMET
(IN NORMAL
POSITION)
MANIFOLD
PRESSURE TAP
DRIP LEG
MANIFOLD
UNION
BURNERS
IGNITOR
A087301-01-00
33
to the combination gas valve on the
furnace. Refer to Table 8 for the recommended gas pipe size for natural gas
and Table 9 for L.P. See Figures 27 &
28 for typical gas pipe connections.
Install a ground joint union inside the
cabinet to easily remove the control
valve assembly. Install a manual
shut-off valve in the gas line outside
the furnace casing. The valve should
be readily accessible to turn the gas
supply on or off. Install a drip leg in the
gas supply line as close to the furnace
as possible. Always use a pipe compound resistant to the action of liquefied
petroleum gases on all threaded connections.
IMPORTANT: When making gas pipe
connections, use a back-up wrench to
prevent any twisting of the control
assembly and gas valve.
Any strains on the gas valve can
change the position of the gas orifices in
the burners. This can cause erratic furnace operation.
IMPORTANT: Do not run a flexible gas
connector inside the unit. If local codes
allow the use of a flexible gas appliance
connector, always use a new listed connector. Do not use a connector which
has previously serviced another gas
appliance. Massachusetts law requires
that all flexible gas connectors be less
than 36”.
The gas pipe grommet in the cabinet
does not seal around a flexible gas connector. It is important to have all
openings in the cabinet burner compartment sealed for proper furnace
operation.
IMPORTANT: Ensure that the furnace
gas control valve is not subjected to
high gas line supply pressures (13.5”
w.c. or above).
DISCONNECT the furnace and its individual shut-off valve from the gas supply
piping during any pressure testing that
exceeds 1/2 PSIG (3.23 kPa or 13"
w.c.).
34
GAS PRESSURE
GAS VALVE
Natural gas supply pressure should
be 5" to 10.5" w.c. LP gas supply
pressure should be 11" to 13" w.c.
This pressure must be maintained
with all other gas-fired appliances in
operation.
This furnace has a 24-volt operated
valve. It has ports for measuring
supply pressure and manifold pressure. A manual control is on the
valve body. It can be set to only the
“ON” or “OFF” positions. See
Figure 36.
The minimum supply pressure to the
gas valve for proper furnace input
adjustments is 5" w.c. for natural gas,
however 6" to 7" is recommended. The
minimum supply pressure is 10.5" w.c.
for LP gas.
!
WARNING
NEVER PURGE A GAS LINE INTO
THE COMBUSTION CHAMBER.
NEVER USE MATCHES, FLAME
OR ANY IGNITION SOURCE FOR
CHECKING LEAKAGE. FAILURE
TO ADHERE TO THIS WARNING
CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY
OR DEATH.
To check for gas leakage, use an
approved chloride-free soap and water
solution, an electronic combustible gas
detector, or other approved method.
FIGURE 36
GAS VALVE
MANUAL CONTROL
TABLE 8
NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)
Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and
specific gravity of 0.60 (natural gas).
Nominal
Length of Pipe, Feet
Iron Pipe
Size, Inches
10
20
30
40
50
60
70
80
1/2
132
92
73
63
56
50
46
43
3/4
278
190
152
130
115
105
96
90
1
520
350
285
245
215
195
180
170
1-1/4
1,050
730
590
500
440
400
370
350
1-1/2
1,600
1,100
890
760
670
610
560
530
After the length of pipe has been determined, select the pipe size which will provide the minimum cubic
feet per hour required for the gas input rating of the furnace. By formula:
Gas Input of Furnace (BTU/HR)
Heating Value of Gas (BTU/FT3)
The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas
(BTU/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.
Cu. Ft. Per Hr. Required =
TABLE 9
LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)
Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11
inches water column inlet pressure).
(Based on a Pressure Drop of 0.5 Inch Water Column)
Nominal
Iron Pipe
Size, Inches 10
20
30
40
50
60
70
80
90
100
125
150
1/2
275
189
152
129
114
103
96
89
83
78
69
63
3/4
567
393
315
267
237
217
196
182
173
162
146
132
1
1,071
732
590
504
448
409
378
346
322
307
275
252
1-1/4
2,205 1,496 1,212 1,039
913
834
771
724
677
630
567
511
1-1/2
3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023
976
866
787
2
6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496
Example (LP): Input BTU requirement of unit, 150,000
Equivalent length of pipe, 60 ft. = 3/4" IPS required.
LP COPPER TUBE SIZING TABLE
Sizing between single or second stage (low pressure) regulator and appliance. Maximum capacity of pipe in thousands of BTU
per hour of undiluted propane gases (at 11" w.c. setting).
Outside Diameter
Copper Tubing,
Type L
10
20
30
40
50
60
80
100
125
150
3/8"
49
34
27
23
20
19
16
14
11
10
1/2"
110
76
61
52
46
42
36
32
28
26
5/8"
206
141
114
97
86
78
67
59
52
48
3/4"
348
239
192
164
146
132
113
100
89
80
7/8"
536
368
296
253
224
203
174
154
137
124
35
LP CONVERSION
IMPORTANT: LP gas from trucks used
to transport liquid-based fertilizers can
contain chemicals that will damage the
furnace. Verify that your gas supplier
does not use the same truck to transport materials other than LP.
This furnace is shipped from the factory for use on natural gas only. For use
on LP gas, a proper conversion is
required.
Conversion of this furnace for use on
LP gas requires conversion kit RXGJFP07 for U.S. and RXGJ-FP08 for
Canada. This kit includes an LP gas
valve.
!
2. Remove the gas valve and manifold assembly.
3. Replace the orifice spuds.
4. Remove the natural gas valve from
the manifold assembly and replace
with the LP valve included in the
kit.
5. Re-attach the manifold assembly to
the unit and connect the gas line to
the gas valve.
7. Check unit for leaks
8. Follow lighting instructions to
put the furnace into operation.
Consult Table 11, if there is any
question concerning orifice sizing.
NOTE: No LP orifices are included
in the kit. LP orifices must be selected based on the altitude of the
installation. See orifice chart.
6. Place the conversion label, included in the kit, adjacent to the CSA
rating plate.
CAUTION
ELEVATIONS ABOVE 2000 FT
REQUIRE THAT THE FURNACE
INPUT RATING BE ADJUSTED AND
THAT THE SIZE OF THE BURNER
ORIFICES BE RE-CALCULATED
BASED ON ELEVATION AND GAS
HEATING VALUE. THE BURNER
ORIFICES MAY (OR MAY NOT)
NEED TO BE CHANGED. SEE THE
SECTION TITLED “HIGH ALTITUDE
INSTALLATIONS” OF THIS BOOK
FOR INSTRUCTIONS.
FIGURE 37
SUPPLY-LINE PRESSURE TAP
NOTE: Order the correct LP conversion kit from the furnace manufacturer.
Furnace conversion to LP gas must be
performed by a qualified installer, service agency, or the gas supplier.
To change orifice spuds for either conversion to LP or for elevation:
1. Shut off the manual gas valve and
disconnect the gas line at the
union ahead of the unit gas valve.
36
SUPPLY-LINE
PRESSURE TAP
SETTING GAS PRESSURE
A properly calibrated pressure gauge
or U-Tube manometer is required for
accurate gas pressure measurements.
!
CAUTION
INPUT RATING BE ADJUSTED
AND THAT THE SIZE OF THE
BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION
AND GAS HEATING VALUE. THE
BURNER ORIFICES MAY (OR MAY
NOT) NEED TO BE CHANGED. SEE
THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS
BOOK FOR INSTRUCTIONS.
Supply Gas Pressure Measurement.
1. With gas shut off to the furnace
at the manual gas valve outside
the unit, remove the line
pressure tap plug on the gas
valve. See Figure 30.
2. Connect a U-Tube manometer to
the pressure tap.
3. Turn on the gas supply and
operate the furnace at 100% and
all other gas-fired units on the
same gas line as the furnace.
4. Note or adjust the supply-line
pressure to give:
A. 5" - 10.5" w.c. for natural gas.
B. 11" - 13" w.c. for LP gas.
5. Shut off the gas at the manual
gas valve and remove the
U-Tube manometer.
6. Replace the supply-line pressure
tap plug before turning on the
gas.
If the supply-line pressure is above
these ranges, install an in-line gas
regulator to the furnace for natural
gas units. With LP gas, have the LP
supplier reduce the supply-line pressure at the regulator.
If supply-line pressure is below these
ranges, either remove any restrictions
in the gas supply piping or enlarge
the gas pipe. See Tables 8 and 9.
With LP gas, have the LP supplier
adjust the supply-line pressure at the
regulator.
!
CAUTION
INPUT RATING BE ADJUSTED
AND THAT THE SIZE OF THE
BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION
AND GAS HEATING VALUE. THE
BURNER ORIFICES MAY (OR MAY
NOT) NEED TO BE CHANGED. SEE
THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS” OF THIS
BOOK FOR INSTRUCTIONS.
➤ MANIFOLD GAS PRESSURE
MEASUREMENT.
1. With the gas to the unit shut off
at the manual gas valve, remove
the outlet pressure tap plug in
the gas valve. See Figure 31.
2. Connect the positive pressure
hose to the pressure tap.
FIGURE 38
REGULATOR CAP
MANIFOLD PRESSURE TAP LOCATION
3. Note the manifold gas pressure
to be:
A. 3.5" w.c. (±.3) for natural
gas .
B. 10.0" w.c. ( ±.5) for LP gas.
4. To adjust the pressure regulator,
remove the regulator cap.
NOTE: Only small variations in
gas pressure should be made by
adjusting the pressure regulator.
5. Turn the adjustment screw, using
a 3/32" allen wrench, clockwise to
increase pressure, or counterclockwise to decrease pressure.
See Figure 32.
MANIFOLD PRESSURE TAP
6. Check manifold gas pressure.
7. Repeat step 5 & 6 if needed.
FIGURE 39
GAS VALVE PRESSURE ADJUSTMENT (3/32" ALLEN WRENCH)
8. Securely replace the regulator
cap.
NOTE: Shut off gas at the manual gas valve and remove the UTube manometer.
9. Replace the manifold pressure
tap plug before turning on
the gas.
NOTE: Do not use gas valve pressure adjustment as a means to
adjust temperature rise. The blower
motor will change speed to maintain
a reasonably constant temperature
rise.
37
ELECTRICAL WIRING
!
WARNING
TURN OFF ELECTRIC POWER AT
FUSE BOX OR SERVICE PANEL
BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE
TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.
!
WARNING
THE CABINET MUST HAVE AN
UNINTERRUPTED GROUND
ACCORDING TO THE LATEST
EDITION OF THE NATIONAL
ELECTRICAL CODE, ANSI/
NFPA70-, OR IN CANADA, THE
CANADIAN ELECTRICAL CODE,
CSA-C22.1 OR LOCAL CODES
THAT APPLY. A GROUND SCREW
IS PROVIDED IN THE JUNCTION
BOX. FAILURE TO PROPERLY
CONNECT THE GROUND WIRE
CAN CAUSE ELECTRICAL
SHOCK RESULTING IN PERSONAL INJURY OR DEATH.
!
the electrical disconnect to the junction
box on the left side of the furnace, inside
the blower compartment. See Figure 33.
For the proper connection, refer to the
appropriate wiring diagram located on the
inside cover of the furnace control box
and in these instructions.
Make all electrical connections in
accordance with the latest edition of
the National Electrical Code
ANSI/NFPA70 – or in Canada, the
Canadian Electrical Code Part 1CSA Standard C22.1 and local codes
having jurisdiction.
NOTE: The electrical junction box may
be moved to the right side if necessary. A
knockout is provided. Seal the opposite
hole with plug provided.
These may be obtained from:
IMPORTANT: 120 vac terminal and neutral terminal polarity must be observed
when making field connections to the furnace. The ignition control WILL not sense
flame if 120 vac and neutral terminals
reversed.
FIGURE 40
JUNCTION BOX LOCATION
UPFLOW
MODELS
WARNING
THIS FURNACE IS EQUIPPED
WITH A BLOWER DOOR SAFETY
SWITCH. DO NOT DISABLE THIS
SWITCH. FAILURE TO FOLLOW
THIS WARNING CAN RESULT IN
ELECTRICAL SHOCK, PERSONAL INJURY OR DEATH.
IMPORTANT: The furnace must be
installed so that the electrical components are protected from water (condensate).
A grounding wire is provided to connect
to the incoming grounding wire from
line power. The furnace must be permanently grounded in accordance with all
national and local codes.
Before proceeding with the electrical
connections, be certain that the service
panel voltage, frequency and phase corresponds to that specified on the furnace rating plate. Maximum over-current
protection is 15 amperes.
Use a separate, fused branch electrical
circuit containing a properly sized fuse or
circuit breaker. Run this circuit directly
from the main switch box to an electrical
disconnect that is readily accessible and
located near the furnace. Connect from
38
➤
DOWNFLOW/
HORIZONTAL
MODELS
National Fire Protection
Association, Inc.
Batterymarch Park
Quincy, MA 02269
Canadian Standards Association
178 Rexdale Boulevard
Rexdale, Ontario, Canada M9W 1R3
ELECTRICAL CHECKS
THERMOSTAT WIRING
Line Power Check
NOTE: Do not use 24 volt control wire
smaller than No. 18 AWG.
The furnace must have a nominal 115
volt power supply for proper operation. If there is not a consistent power
supply, contact a licensed electrician
to correct the problem.
1. With the blower compartment door
off, manually hold the push button
door switch in.
2. Call for heat at the thermostat.
3. With the unit operating, use a voltmeter to measure the voltage from
any 120 VAC terminal to any neutral connection.
4. The voltage should be a nominal
115 volts (acceptable 105120VAC).
This test should be made with the unit
in full operation.
Polarity Check
Proper line voltage polarity, or phasing, is a must for this furnace to operate. Use a volt meter to make this
check.
1. With the blower compartment door
off, manually hold the push button
door switch in.
2. Use a voltmeter to measure the
voltage from any 120 VAC terminal
to any bare metal ground on the
furnace.
115 volts (acceptable 105120VAC).
4. Use a voltmeter to measure the
voltage from any neutral terminal
to the bare metal ground on the
furnace.
5. The voltage should be approximately (0) volts.
6. If the voltage from any 120 VAC
terminal to ground is approximately zero (0) volts and the voltage
from a neutral to ground is a nominal 115 volts, the polarity is
reversed.
7. To correct the problem, either
reverse the hot and neutral wires
to the furnace or have a licensed
electrician check the building
wiring.
Control Voltage Check
1. With the blower compartment
door off, manually hold the push
button door switch in.
2. Call for heat at the thermostat.
3. With the unit operating, use a
voltmeter to measure the voltage
from control voltage terminal “W”
to terminal “C” on the furnace
control board.
24 volts (Acceptable 105120VAC).
FIGURE 41
24-VOLT TERMINALS
Wire all thermostats to the 24V connections on the integrated furnace control. See Figures 34, 35, and 36.
NOTE: A larger wire gage may be be
required for longer lengths of thermostat wire.
For proper installation of the Variable
Output Thermostat, follow the
“Thermostat Installation, Programming
and Troubleshooting Manual” included
as section II of this manual. For proper
installation of a Single-Stage or TwoStage Thermostat, see the Installation
Instructions included with the thermostat.
➤ FURNACE OPERATION USING
MODULATING, SINGLE-STAGE, AND
TWO-STAGE THERMOSTATS
The modulating furnace with the UT
Electronic Controls IFC is also capable
of operating with a single-stage or a
two-stage thermostat as well as the
modulating thermostat. Furnaces
equipped with part # 62-24174-01 (rev
-02 or newer) or 62-24174-02 (all revisions) will operate with either singlestage or two-stage thermostats as a
modulating system using an algorithm
that utilizes three distinct firing rates;
40%, 65% and 100% of the furnace
heating capacity (See below for operation of each).
Figures 42, 43, and 44 detail how to
wire the modulating furnace for operation with a modulating thermostat, a
single-stage thermostat and a twostage thermostat respectively.
➤ FURNACE OPERATION WITH A
MODULATING THERMOSTAT
As described previously in this manual,
operation with a modulating thermostat
when installed as shown in Figure 42
is fully modulating between 40% and
100% of furnace capacity. The firing
rate is first determined by the thermostat and then sent to the furnace. This
is the optimum mode of operation and
will give the best temperature control
with minimal temperature variation
from the desired set point.
With a single stage thermostat
(installed as shown in Figure 43),
during a call for heat, the furnace will
operate as follows:
Phase 1: 0 to 5 minutes = 40% of
furnace capacity
Phase 2: 5 to 12 minutes = 65% of
furnace capacity
Phase 3: After 12 minutes = 100 %
of furnace capacity
NOTE: If the call for heat ends during any phase, the furnace will terminate immediately at the firing rate of
that phase.
If switches 1 & 2 of SW2 are in the
“ON” position (See Figure 47), the
furnace will always operate at 40%
with a single stage thermostat
installed as shown in Figure 36.
THIS CONFIGURATION IS NEITHER RECOMMENDED NOR
APPROVED.
➤ FURNACE OPERATION WITH A
SINGLE STAGE THERMOSTAT
To operate the furnace with a singlestage thermostat, set switches 1 & 2 of
SW2 (See Figure 47) to the “OFF”
position. Note that these switches
should be in the “OFF” position from
the factory. The lack of the modulating
“V” signal will automatically be sensed
as a single-stage thermostat and the
furnace will operate accordingly.
This test should be made with the
unit in full operation.
39
➤
FIGURE 42
WIRING DIAGRAM FOR MODULATING HEAT
MODULATING THERMOSTAT
V / W2
➤
FIGURE 43
WIRING DIAGRAM FOR SINGLE-STAGE HEAT
1-STAGE ELECTRONIC THERMOSTAT*
*
**
40
NO MECHANICAL THERMOSTATS.
40%, 65%, and 100% FIRING RATE IN SINGLE-STAGE OPERATION. 40% FIRING RATE IN TWO-STAGE OPERATION
(DIP SWITCH SET SW2 — SWITCHES 1 & 2 ON).
FIGURE 44
WIRING DIAGRAM FROM TWO-STAGE HEAT
2-STAGE ELECTRONIC THERMOSTAT*
*
**
NO MECHANICAL THERMOSTATS.
40%, 60%, and 100% FIRING RATE IN SINGLE-STAGE OPERATION. 40% FIRING RATE IN TWO-STAGE OPERATION
(DIP SWITCH SET SW2 — SWITCHES 1 & 2 ON).
*** 65% and 100% FIRING RATE IN TWO-STAGE OPERATION (W & W2 ENERGIZED).
FURNACE OPERATION WITH A
TWO-STAGE THERMOSTAT
To set the furnace for operation with
two-stage thermostats, set switches 1 &
2 of SW2 to the “ON” position (See
Figure 47). Note that these switches
should be in the “OFF” position from
the factory. With both switches in the
“ON” position, the furnace can still recognize a “V” signal present and will still
operate with a modulating thermostat.
However, with both switches of SW2 in
the “ON” position, the furnace is set to
operate with a two-stage thermostat as
well.
With a two-stage thermostat (installed
as shown in Figure 44) and switch settings configured as described above,
during a call for heat, the furnace will
operate as follows:
First Stage
(“W”=ON and “W2”=OFF)
40% of furnace capacity always
Second Stage
(“W”=ON and “W2”=ON)
Phase 1: 0 to 5 minutes = 65% of furnace capacity
Phase 2: After 5 minutes = 100% of
furnace capacity
NOTE: If the call for heat ends during
any phase and/or stage, the furnace
will terminate immediately at the firing
rate of that phase and/or stage.
ACCESSORIES
FIELD-INSTALLED
OPTION ACCESSORIES
ELECTRONIC AIR CLEANER
Line voltage power can be supplied from
the screw terminal “EAC”, see Figure 45,
and a line voltage neutral screw terminal
on the control board. This will power the
electronic air cleaner whenever the
ECM2+ blower is operating and delivering the recommended minimum CFM.
The 60 and 75 KBTU models, which are
capable of a maximum delivery of 1200
FIGURE 45
EAC TERMINAL
CFM, will operate the electronic air
cleaner at 500 CFM and above. The
90, 105 and 120 KBTU models,
which are capable of a maximum
delivery of 2000 CFM, will operate
the electronic air cleaner at 800
CFM and above. These limits are set
to prevent excessive production of
ozone at the lower airflows of the
modulating furnace and are based on
average requirements of commercially available electronic air cleaners.
The continuous fan speeds are set to
always provide adequate airflow for
electronic air cleaner operation.
HUMIDIFIER
The humidifier contacts (labeled
HUMIDIFIER on the IFC) are “dry”
contacts on the IFC. This means
that the terminals are connected
directly to the contacts of a boardmounted relay. The coil of the relay
is controlled by the microprocessor
of the IFC. The coil is engaged
roughly any time the heat speed
blower is engaged so that humidification is active any time the heat
blower is running. In addition to this
control, on 24 VAC humidifiers or
humidifiers controlled by a 24 VAC
control circuit, an optional 24 VAC
humidistat can be installed (see
Figure 46). With the optional
humidistat, two separate conditions
must be met before humidification of
the conditioned space can begin: 1)
There must be a heat call and the
heat speed blower must be running
and 2) The humidistat must determine that there is a need for humidification.
41
FIGURE 46
WIRING FOR OPTIONAL HUMIDIFIER
LOW VOLTAGE
CONTROL WIRING
I681
42
DEHUMIDIFICATION IN COOLING
OPERATION
Dehumidification in the cooling mode
can be accomplished by two different
methods. Both methods will reduce the
amount of airflow in cooling by 15%.
This reduced airflow will cause more
water to condense on the evaporator
coil thus reducing the humidity in the
conditioned space.
IMPORTANT: The manufacturer
requires that all cooling systems
installed with either dehumidification
feature enabled MUST have a coil of the
type with an expansion valve. RCBA
coils can be used with the feature(s)
enabled provided that there is an
expansion valve kit installed with the
coil. In addition to these requirements,
RCGA, RCBA and RCHA coils must
have a freeze-stat (part #RXRX-AM01)
installed to prevent possible coil freezeup. Note that the RCBA coils must have
BOTH an expansion valve kit and a
freeze-stat installed.
Method A: THERMOSTAT DEMAND
DE-HUMIDIFICATION
This method for dehumidification relies
on an algorithm in the modulating thermostat (part #41-24312-04) to calculate
a need for dehumidification based on
the number and frequency of cooling
calls over a specified period of time.
The feature is enabled on the thermostat interface panel. Please read and
follow the instructions for the modulating thermostat to enable this feature.
Please note that the thermostat can
only estimate when there is a need for
dehumidification by looking at the
recent history of cooling calls. This is
not a true measurement of humidity.
For true humidity measurement, a
humidistat must be installed per the
instructions in method B below.
Method B: ON-DEMAND DE-HUMIDIFICATION–REFERENCE FIGURES
40A THRU C
On UTECH IFC Revision –03 (6224174-01 rev 03)or newer (After May
12, 2004) or all revisions of 62-2417402, an additional method for dehumidification was added to the function of the
IFC. This method is not available on
units constructed before this date.
The following methods for dehumidification utilize the most accurate means for
sensing humidity. A humidistat should
be installed to the control board “YL” or
“DEHUM” and “R” terminals.
ON DEMAND DEHUMIDIFICATION
ON UTECH IFC #62-24174-01
REVISION 03 (62-24174-01 Rev -03)
A humidistat should be installed to the
control board “YL” and “R” terminals.
PLEASE NOTE THAT TWO-STAGE
COOLING AND ON-DEMAND DEHUMIDIFICATION CANNOT BE USED
AT THE SAME TIME (IFC REV. 03
ONLY). The dip switch position #6 of
bank SW-1 is used to select between
either two-stage cooling or on-demand
de-humidification, both features can not
be used at the same time because
there is only one input used for both.
Also, if neither feature is to be used, it
does not matter if the dip switch is in
the “ON” or “OFF” position. Any
humidistat can be used provided it is of
the type that can handle 24 volts and
opens the contacts when there is a
need for de-humidification.
For proper installation of On-Demand
De-Humidification, ensure the following:
A. Install one wire from one humidistat
contact terminal to the IFC “YL” terminal and another wire from the
remaining humidistat contact terminal to the IFC “R” terminal.
B. When installing, be sure to use a
humidistat and NOT a de-humidistat.
C. Position dip switch #6 of bank SW-1
to the “ON” position.
D. It is not possible to use two-stage
cooling and de-humidification feature at the same time.
NOTE: When the dip switch position #6
of bank SW-1 is in the on position, a 24
volt signal from the humidistat must be
supplied at all times to keep the blower
running at the correct cooling speed.
When the 24 VAC signal is absent, the
IFC assumes there is a need for dehumidification and operates the blower
at the reduced rate. This is what is
known as “reverse-logic”. In other
words, when a 24 VAC signal is present, normal operation occurs (100%
cooling CFM), however, when there is
no signal present, the IFC goes into the
dehumidification mode and reduces the
airflow by 15%. This could be confusing and will cause the cooling speed to
be reduced by 15% if the dip-switch is
in the “on” position but no humidistat is
connected.
ON DEMAND DEHUMIDIFICATION
IFC #62-24174-02
For IFC Revision #62-24174-02 (AVAILABLE 2ND QUARTER 2005) or later, a
new dehumidification terminal has been
added to the thermostat terminal block.
This terminal will permit the user to
install dehumidification without the need
to manipulate any dip-switches.
However, to activate the ODD feature,
a jumper located at position J5
(between the thermostat terminal block
and dip switch bank SW-2 on the IFC –
see Figure 47) must be removed and
discarded. This jumper applies 24 volts
to the “dehum” terminal at all times in
order to prevent the control from reverting to the lower (dehumidification)
speed when no voltage is applied.
IMPORTANT: Do not remove the
jumper at J5 unless a humidistat is
installed to the “DEHUM” terminal of
the IFC. In addition, the control allows
the use of two-stage cooling and dehumidification at the same time and separate cooling airflows for high efficiency
(up to16 SEER) cooling. (see section
labeled “FURNACE INSTALLATION
WITH HIGH EFFICIENCY PREMIUM
COOLING SYSTEMS”).
For proper installation of OnDemand De-Humidification, ensure
the following:
A. Install one wire from one humidistat contact terminal to the IFC
“DEHUM” terminal and another
wire from the remaining humidistat contact terminal to the IFC
“R” terminal.
B. When installing, be sure to use a
humidistat and NOT a de-humidistat.
C. The jumper at position J5 on the
control (see Figure 47) has been
removed.
FIGURE 47
UT Electronic Controls IFC. 62-24174-02
Shown with Nec. Jumper location shown
to activate dehumidification.
Remove this jumper (J5)
to enable dehumidification
43
FIGURE 48
WIRING FOR OPTIONAL DEHUMDIFIER
HUMIDISTAT USED TO CONTROL DEHUMIDIFICATION IN COOLING
IFC 62-24174-01 REV. 03 ONLY! POSITION #6
OF SW1 MUST BE IN “ON” POSITION
REMOVE
FOR
DEHUM
ENABLE J5
J5
IFC 62-24174-02: REMOVE THIS JUMPER
(J5) TO ENABLE DEHUMIDIFICATION
(IFC 62-24174-01 REV. 03) OR DEHUM (IFC 62-24174-02 -ALL
REVISIONS)
HUMIDISTAT
(24V)
(CONTACTS OPEN
WHEN HUMIDITY
IS ABOVE SET POINT)
FIGURE 49
WIRING FOR OPTIONAL DEHUMIDIFIER WITH HUMIDIFIERRING FOR OPTIONAL DEHUMDIFIER
AND DEHUMIDIFIERHUMIDISTAT
WITH HUMIDIFIER
USED TO CONTROL BOTH HUMIDIFIER IN HEATING
AND DEHUMIDIFIER IN COOLING (HUMIDIFIER WITH INTEGRAL
POWER SUPPLY)
REMOVE
FOR
DEHUM
ENABLE
J5
IFC
IFC 62-24174-02: REMOVE
THIS JUMPER (J5) TO ENABLE
DEHUMIDIFICATION
(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02
-ALL REVISIONS)
HUMIDISTAT
(24V)
(CONTACTS
OPEN WHEN
HUMIDITY IS
ABOVE SET
POINT)
NEUTRAL OR COMMON
HUMIDIFIER WITH
INTERNAL
+110VAC OR 24VAC POWER SUPPLY
SPST RELAY
W/ N.O CONTACTS
RATED 24V COIL
AND 24V OR 110V
CONTACTS AS
NECESSARY FOR
HUMIDIFIER
44
FIGURE 50
WIRING FOR OPTIONAL DEHUMIDIFICATION WITH HUMIDIFIER AND SEPARATE POWER
SUPPLY.WIRING DIAGRAM FROM TWO-STAGE HEAT
HUMIDISTAT USED TO CONTROL BOTH HUMIDIFIER IN HEATING
AND DEHUMIDIFIER IN COOLING (110V HUMIDIFIER WITHOUT
INTEGRAL POWER SUPPLY)
REMOVE
FOR
DEHUM
ENABLE
J5
IFC 62-24174-02: REMOVE
THIS JUMPER (J5) TO ENABLE
DEHUMIDIFICATION
(IFC 62-24174-01 REV 03) OR DEHUM (IFC 62-24174-02
-ALL REVISIONS)
HUMIDISTAT
(24V)
(CONTACTS
OPEN WHEN
HUMIDITY IS
ABOVE SET
POINT)
SPST RELAY
W/N.O CONTACTS
RATED 24V COIL
AND 24V OR 110V
CONTACTS AS
NECESSARY FOR
HUMIDIFIER
NEUTRAL OR COMMON
HUMIDIFIER WITH
EXTERNAL 110V
OR 24V POWER
+110VAC OR 24VAC SUPPLY
110V OR 24V
POWER SUPPLY
AS NECESSARY
FOR HUMIDIFIER
RXPF-F02 SYSTEM
INSTALLATION WITH
HEAT PUMPS (REFER TO
WIRING DIAGRAMS OF
FIGS 51 THRU 53)
As of May 12, 2004, the modulating
furnace systems can be installed
with heat pump systems provided
that the IFC is part number 6224174-01 REV –03 or greater or 6224174-02 and that an RXPF-F02
fossil fuel kit is used to install the
system.
Refer to Figures 51 thru 53 for various installation wiring diagrams covering different defrost controls,
refrigerant types and optional heatpump monitor installations. For further instructions, refer to the instructions delivered with the fossil fuel kit.
System Operation with
Modulating Gas Furnace with
RXPF-F02
NOTE: Modulating control must be
part number 62-24174-01 Rev. –03
or newer or 62-24174-02.
NOTE: Both dip switches of SW-2 of
the modulating control (IFC) must be
in the “ON” position (timed twostage heat operation).
NOTE: Thermostat must have a
“W2” connection for second-stage
heat when configured for a modulating furnace.
(continued on next page)
45
A. First-Stage Heat Call (Thermostat
“Y”+”B”)
(1) The system receives a demand
for heat from the indoor thermostat (“Y” and “B”)
“B” is energized when the indoor
thermostat is set to “HEAT”
“Y” is energized when the indoor
thermostat calls for heat.
(2) “B” is routed directly to the outdoor unit for the heat pump heating control system. (Usually a
reversing valve).
(3) “Y” is routed to the outdoor thermostat:
Condition 1: When the outdoor
air temperature is above the setpoint of the outdoor thermostat
and the indoor thermostat only
senses a need for first-stage
heat, the operation is normal
heat pump. Both the cooling
contactor on the condenser and
cooling speed fan on the control
board (IFC) (via “Y”) are energized at this point.
Condition 2: When the outdoor
air temperature is below the setpoint of the outdoor thermostat
and the indoor thermostat only
senses a need for first-stage
heat, heating control is switched
directly to the modulating gas
furnace by energizing “W” on the
modulating control (IFC) alone.
This will give 40% (low fire) gas
heat until either a second-stage
heat call is present or the thermostat heat call is satisfied. At
this point, the thermostat has
energized both “Y” and “B”, but
the fossil fuel kit changes the “Y”
signal into a “W” call to the modulating control. The cooling contactor is de-energized during this
mode and the compressor and
condenser fan are turned off.
The reversing valve (via “B”) is energized throughout Condition 1 or 2,
but is ignored and has no consequence in Condition 2 since the
compressor and condensing fan are
not running in Condition 2.
B. Second-Stage Heat Call
(Thermostat “W2”+”Y”+”B”)
(1) When the system thermostat
determines that the indoor air
temperature is significantly
below the setpoint of the thermostat, it will call for secondstage heat. Second-Stage heat
with a modulating furnace as
installed and wired per this document will be gas heat starting
at 65% of full fire.
“W2”, “Y” and “B” are simultaneously energized by the thermostat.
“W2” is routed to the modulating
furnace control to energize both
“W” and “V/W2” on the modulating control board (IFC) (through
the relay provided with the
RXPF-F02). This turns on gas
heat at 65% for seven minutes
followed by 100% gas heat until
the Second-Stage heat call is
satified.
46
“Y” is turned off by the FFK IWB
(Fossil Fuel Kit Interface Wiring
Board) so that the cooling contactor is NOT energized. NOTE:
At this point, “Y” from the thermostat to the FFK IWB will be
energized, however, neither “Y”
between the FFK IWB and the
cooling contactor nor “Y”
between the FFK IWB and the
modulating control (IFC) will be
energized.
The reversing valve (via “B”) is
energized during the Second-Stage
heat call, but is ignored and has no
consequence on the system since
the compressor and condensing fan
will not be running during SecondStage Heat.
C. Defrost (Thermostat “Y”+”B”)
(Defrost Control “W2”or”D”)
(1) The system receives a backup
heat demand from the outdoor
unit defrost control (Defrost
Control “W2”or”D”)
(2) When the defrost control determines there is a need to defrost
the coil, the heating call is rerouted by the defrost control
back to the FFK IWB. The
Defrost control also forces the
reversing valve to run the AC
system in cooling.
(3) The Defrost mode heat call from
the outdoor unit is routed to the
FFK IWB, through the Plenum
Sensor and finally to “W” and
“V/W2” on the modulating control (IFC). The modulating furnace begins heating at 65% of
full fire for seven minutes followed by 100% until the
heat/defrost call is satisfied.
(4) A plenum switch is provided to
control heat in the defrost mode.
This switch prevents the evaporator coil from overheating when
gas heat is running in the
defrost mode.
(5) The “Y” (Cooling) circuit remains
energized on the modulating
control (IFC). This means that
the furnace is running at either
65% or 100% of full fire heat
with cooling speed blower.
(6) The compressor and condensing fan of the cooling system will
be running in the cooling direction during the Defrost mode to
transfer heat to the condensing
coil to melt away any frost or ice
build-up on the condenser.
The reversing valve (via B) is deenergized during the defrost cycle.
During defrost mode, “B” from the
thermostat through the FFK IWB
and out to the defrost control will be
energized, but the circuit from the
defrost control to the reversing
valve will NOT be energized as the
defrost control forces the reversing
valve into cooling.
D. Call for Emergency Heat
(Thermostat “E”)
(1) In the Emergency Heat mode,
the indoor thermostat routes all
heat demands (first- and sec-
ond-stage) to the modulating
furnace so that, with an
Emergency heat call from the
thermostat, gas heat will turn
on at 65% of full fire for
seven minutes followed by
100% until the Emergency
Heat call is satisfied.
The reversing valve (via “B”) is
energized during the Emergency
Heat call, but is ignored and has
no consequence on the system
since the compressor and condensing fan will not be running
during Emergency Heat.
E. Call for Cooling (Thermostat
“O”, “Y” & “G” or “Y” & “G”)
(1) In the cooling mode, the system receives a demand for
cooling from the indoor thermostat.
When the thermostat recognizes a need for cooling, “Y”
is energized by the thermostat and the FFK IWB uses
this signal to energize “Y” to
the modulating control (IFC)
and to the cooling contactor.
In cooling, “B” is de-energized and “O” is energized.
This sets the reversing valve
for the cooling mode.
(2) “O” is routed to the outdoor
unit for the heat pump cooling control system (usually
the “Low-Ambient” relay or
alternate reversing valve
control system.)
F. Call for Continuous Fan
(Thermostat “G”)
(1) The system receives a
demand from the indoor thermostat “G”.
(2) The fan call is routed directly
to the “G” terminal on the
modulating control (IFC).
OTHER ACCESSORIES
AVAILABLE
These kits are available through the
finished goods department.
CONCENTRIC VENT TERMINATION KIT = RXGY-E03
HORIZONTAL, TWO-PIPE TERMINATION KIT = RXGY-D02, RXGYD03, OR RXGY-D04
CONDENSATE PUMP KIT: RXGYB01
NEUTRALIZER KIT: RXGY-A01
EXTERNAL BOTTOM FILTER
RACK: RXGF-CB
EXTERNAL SIDE FILTER RACK:
RXGF-CA
These parts are available through
ProStock parts department.
PROGRAMMABLE MODULATING
THERMOSTAT: 41-24312-04
NON-PROGRAMMABLE MODULATING THERMOSTAT: 41-2534701
FIGURE 51
RXPF-F02 WITH DEMAND-BASED DEFROST CONTROL, SINGLE-PHASE CONDENSOR, R410A REFRIGERANT WITH RHEEM/RUUD MODULATING
GAS FURNACE (TVA COMPLIANT)
47
FIGURE 52
RXPF-F02 WITH DEMAND-BASED DEFROST CONTROL, SINGLE-PHASE CONDENSOR, R22 REFRIGERANT WITH RHEEM/RUUD MODULATING
48
FIGURE 53
RXPF-F02 WITH DEMAND-BASED DEFROST CONTROL, THREE PHASE CONDENSOR, R22 REFRIGERANT WITH RHEEM/RUUD MODULATING
49
HIGH ALTITUDE INSTALLATIONS
-GFD/-GGD -HIGH
ALTITUDE OPTION #278
! WARNING
FOR -GGD-06 MODELS, A PRESSURE SWITCH CHANGE IS NOT NECESSARY AT ANY ELEVATION. FOR GGD-07 MODELS, A PRESSURE
SWITCH CHANGE IS REQUIRED AT
ELEVATIONS ABOVE 8,000 FT. FOR
ALL OTHER -GFD/-GGD FURNACES,
A PRESSURE SWITCH CHANGE IS
REQUIRED AT ELEVATIONS ABOVE
5,000 FT. OPTION CODE -278 OR THE
APPROPRIATE HIGH-ELEVATION KIT
WILL CONVERT THE FURNACE FOR
USE ABOVE THE APPROPRIATE ELEVATION STATED HERE. DO NOT
INSTALL THE -278 OPTION FURNACE
OR THE HIGH ALTITUDE KIT BELOW
THE STATED ELEVATION. DOING SO
CAN CAUSE SERIOUS PERSONAL
INJURY OR DEATH OR EQUIPMENT
FAILURE.
Furnaces can be ordered from the factory already converted for high altitude
elevations. The factory option for high
altitude elevations would be ordered as
a 278 option (example: a 105k BTU
upflow furnace which is factory converted for high altitude elevations would
have the model number -GFD10EZCMS278). These factory converted
furnaces come with pressure switches
for high-altitude elevations already
attached. Also, different burner orifices
are installed at the factory which are one
drill size smaller (#51 DMS) than standard -GFD/GGD gas furnaces (#50
DMS). The smaller orifice is installed to
accommodate for average heating values expected in most high altitude areas
and a required 4% per thousand feet
reduction in input as specified by the
National Fuel Gas Code (NFGC).
Specific orifices should always be recalculated for all high altitude installations
as outlined below. Orifices should be
changed, if necessary, based on gas
heating value and elevation.
HIGH ALTITUDE CONVERSION
KITS AND OPTIONS
!
WARNING
FOR -GGD-06 MODELS, A PRESSURE SWITCH CHANGE IS NOT NECESSARY AT ANY ELEVATION. FOR GGD-07 MODELS, A PRESSURE
SWITCH CHANGE IS REQUIRED AT
ELEVATIONS ABOVE 8,000 FT. FOR
ALL OTHER -GFD/-GGD FURNACES,
A PRESSURE SWITCH CHANGE IS
REQUIRED AT ELEVATIONS ABOVE
5,000 FT. OPTION CODE -278 OR THE
APPROPRIATE HIGH-ELEVATION KIT
WILL CONVERT THE FURNACE FOR
50
USE ABOVE THE APPROPRIATE
ELEVATION STATED HERE. DO NOT
INSTALL THE -278 OPTION FURNACE OR THE HIGH ALTITUDE KIT
BELOW THE STATED ELEVATION.
DOING SO CAN CAUSE SERIOUS
PERSONAL INJURY OR DEATH OR
EQUIPMENT FAILURE.
fices are calculated and sized based
on a sea level Natural Gas heating
value of 1075 BTU per cubic ft.
Regional reduced heating values
may nullify the need to change orifices except at extreme altitudes.
Table 10 shows some quick conversions based on elevation and gas
heating value. This table is combined and simplified from Tables F1
and F4 of the NFGC.
HIGH ALTITUDE FIELD
CONVERSION KITS (GFD MODELS)
MODEL
-GFD-06XXXXX
-GFD-07XXXXX
-GFD-09XXXXX
-GFD-10XXXXX
-GFD-12XXXXX
INPUT(BTU)
60,000
75,000
90,000
105,000
120,000
The following are examples of orifice
sizing using the National Fuel Gas
Code Appendix F. For a simplified
estimation of orifice size based on
heating value and elevation use
Tables 10 and 11. However, calculations are the best method.
KIT NO.
RXGY-F06
RXGY-F07
RXGY-F06
RXGY-F05
RXGY-F05
HIGH ALTITUDE FIELD
CONVERSION KITS (GGD MODELS)
MODEL
-GGD-06XXXXX
-GGD-07XXXXX
-GGD-09XXXXX
-GGD-10XXXXX
-GGD-12XXXXX
Example: 900 BTU/ft3 Regional
Natural Gas Heating Value
I/H=Q
15000 / 900 = 16.68 ft3/hr
INPUT(BTU) KIT NO.
60,000
No Kit Required
75,000
RXGY-F23
(8000 ft and
above only)
90,000
RXGY-F24
105,000
RXGY-F25
120,000
RXGY-F26
I = Sea Level input (per burner):
15000
H = Sea Level Heating Value: 900
Q = 16.68 ft3 Natural Gas per hour.
From Table F.1 of National Fuel Gas
Code Handbook, 2002 (3.5 w.c. column)
Orifice required at Sea Level: # 48
Orifice Selection for High Altitude
Applications
Natural Gas
! CAUTION
DO NOT ATTEMPT TO ADJUST
MANIFOLD GAS PRESSURE FOR
ELEVATION ON (-)GGD OR (-)GFD
FURNACE MODELS. THIS METHOD
IS NOT PERMITTED ON THESE
MODELS!
Caution. The National Fuel Gas Code
(NFGC) guidelines should be followed
when converting these furnaces for
high altitude operation.
34” 90 Plus furnaces (except for opt
-278 models) installed at high elevations require the installation of a high
altitude kit for proper operation. The
high altitude kit consists of a high altitude pressure switch that replaces the
pressure switch attached to the induced
draft blower.
The pressure switch must be installed
at elevations above those listed.
Elevations above 2000 ft. require the
furnace to be de-rated 4% per thousand feet. NOTE: Factory installed ori-
From Table F.4 of National fuel Gas
Code Handbook, 2002
Orifice required at 5000 ft. elevation
(4% de-rate per thousand ft): # 50
Example: 1050 BTU/ft3 Regional
Natural Gas Heating Value
I/H=Q
15000 / 1050 = 14.63 ft3/hr
I = Sea Level input (per burner):
15000
H = Sea Level Heating Value: 1050
Q= 14.28 ft3 Natural Gas.
code Handbook, 2002 (3.5 w.c. column)
Orifice required at Sea Level: # 50
code Handbook, 2002
TABLE 10
Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)
IMPORTANT: For 90+ Furnaces only. Do not use this chart for any 80+ Furnace.
Burner Input (per burner) 25,000 BTU @ Sea Level
Annual Avg. Heat
Value (btu per ft3)
850
900
1000
1075
1170
Sea level
to 1999 ft
47
48
49
50
51
2000 to
2999 ft
48
49
50
51
51
3000 to
3999 ft
48
49
50
51
52
4000 to
4999 ft
49
49
50
51
52
5000 to
5999 ft
49
50
51
51
52
6000 to
6999 ft
49
50
51
52
53
7000 to
7999 ft
50
50
51
52
53
8000 to
8999 ft
50
51
52
52
53
51
17.52
16.36
15.2
13.92
12.77
47
48
49
50
51
1175
1078
987
917
856
808
51
14,400
15,000
50
49
48
47
46
51
50
49
48
47
46
13,800
51
51
50
49
48
47
13,200
52
51
50
49
48
47
12,600
52
51
50
49
49
47
12,000
52
51
51
50
49
48
11,400
52
52
51
50
49
48
10,800
53
52
51
50
50
49
10,200
53
52
52
51
50
49
9,600
53
53
52
51
51
50
9000-9999
Divide the individual burner capacity (15,000 for 90 plus) by the Heat Value for the site to determine the Cubic Foot value at Sea Level, or divide
burner capacity by the Cubic Foot value for the Heat Value. Once you have either the Cubic Foot Value or the Heat Value you can estimate the Sea
Level orifice for the site. To select the corresponding high altitude orifice, locate the site elevation on the chart above and the orifice required at Sea
Level from your calculation in the first column. The correct high altitude orifice that must be installed in each individual burner is the intersection of
these two points on the chart above.
NOTE:
Heat Value at Sea Level, for the location of the installation, is available from the Natural Gas Supplier to that site. Orifices for all altitudes are based
on Sea Level values.
All calculations are performed by using the first three columns of information only. Before beginning any calculations, determine the
individual burner Btu size and heating value at Sea Level for the installation site. Each value shown in the Heat Value column is per
burner at 3.5" W.C.
Final Firing Rate per Burner
18.57
46
NATURAL GAS QUICK REFERENCE CHART FOR ORIFICE SELECTION, AT 3.5" W.C. AND APPROXIMATE FINAL FIRING RATES
Sea
Sea Level
90 Plus Heat ELEVATION CHART (NFG recommended orifice based on 4% derate for each 1000 foot of elevation, based
Level
Cubic
Value at
on the intersection of the orifice required at Sea Level and the elevation required below)
Orifice
Foot at
15,000 Btu’s
Size
3.5" W.C.
per Burner
0-999
1000-1999
2000-2999
3000-3999
4000-4999
5000-5999
6000-6999
7000-7999
8000-8999
90 Plus ONLY models with 15,000 Btu's per Burner. DO NOT USE THIS CHART FOR ANY 80 PLUS MODEL.
SUPPLEMENTAL ORIFICE SIZE CHART
TABLE 11
LP Gas is a manufactured gas that has
consistent heating value across most
regions.
Orifice Ordering Information
Orifice sizes are selected by adding
the 2-digit drill size required in the orifice part number. Drill sizes available
are 39 through 64; metric sizes available 1.10mm (-90) and 1.15mm (-91):
The NFGC guidelines are used with the
following exception:
Orifice Part Number 62-22175-(drill
size)
LP GAS AT HIGH ALTITUDE
ELEVATIONS
The recommended LP Gas high altitude
orifice selections differ slightly in that
the NFGC LP orifice chart, as they are
not accurate for the (-)GFD or (-)GGD
gas furnace. The National Fuel Gas
Code LP orifices are based on an 11” of
water column pressure at the orifice,
which differs from products that use 10”
of water column at the orifice. This difference requires a deviation from the
NFGC orifice size recommendations.
The Sea Level input should still be
reduced by 4% per thousand ft. and the
orifice size must be selected based on
the reduced input selection shown in
Table 12.
Example 1:
#60 drill size orifice required
Part #62-22175-60
Example 2:
1.15mm drill size orifice required
Part #62-22175-91
TABLE 12
LP Gas Orifice Drill Size and per burner de-rate by elevation based
on 15,000 btu 90+ burners.
IMPORTANT: For 90+ Furnaces only. Do not use this chart for any
80+ Furnace.
Altitude
0 to 2000 ft.
2001 to 3000
3001 to 4000
4001 to 5000
5001 to 6000
6001 to 7000
7001 to 8000
8001 to 9000
9001 to 10000
52
Input (per
burner) 15000
15000
13200
12600
12000
11400
1080
10200
9600
9000
Orifice
Size
1.15 mm (factory)
1.15 mm
1.10 mm
#58
#59
#60
#62
#63
#64
ZONING SYSTEMS
The manufacturer does not currently
provide or support zoning with modulating furnace. However, zoning systems
can be installed with the system as long
as the zoning equipment manufacturers
specifications and installation instructions are met and followed.
The preferred zoning method is to use
a “bypass” system which is properly
installed for maximum efficiency. In
these systems, excess air is routed
back through the system to be used
again – this is opposed to a “dump”
system in which excess air is routed to
a zone where it is expected that the
extra heat or cooling would be least
noticed.
If installed as a “bypass” system, the
installation must have an optional
freeze stat installed to prevent the coil
from icing with excess bypass cooling.
Also, if the zoning equipment manufacturer provides a limit switch (usually
provided by the zoning manufacturer),
this limit must be installed in the system
to prevent the furnace from overheating.
FURNACE INSTALLATION
WITH HIGH-EFFICIENCY
PREMIUM COOLING
SYSTEMS
Furnace installation with Rheem/Ruud
-ARA or -ARL outdoor condensing units
can provide high efficiency (up to 16
SEER) cooling operation when combined with proper evaporator coil. For
listed cooling equipment combinations,
see the -ARA or -ARL specification
sheets. Using Tables 13 and 14 and literature provided with the cooling equipment, the installer needs to make sure
that the proper evaporator coil, condensing coil and airflow is configured to
achieve rated efficiency.
UP TO 16 SEER COOLING
OPERATION
Check the revision number of the integrated furnace control (IFC) to determine how best to configure your furnace for high SEER operation.
IFC #62-24174-02
To achieve high SEER operation, turn
dip switch #6 of bank SW1 to the “on”
position. This will enable the furnace
operation for 16 SEER. Actual SEER
values will vary and depend on the
equipment combination. Consult the
specifications sheets and installation
instructions of the cooling equipment
purchased for a listing of the SEER ratings for a specific combination.
ALL OTHER INTEGRATED
FURNACE CONTROLS
High SEER operation with IFC’s
other than 62-24174-02 may not
achieve rated performance or
desired comfort levels. For these
older models, there are no additional
adjustments necessary to the furnace. For optimum performance,
replace with IFC #62-24174-02.
A NOTE ABOUT
DEHUMIDIFICATION:
High SEER systems may require the
use of the onboard dehumidification
feature of this system. Be sure to
consult the section titled “ON
DEMAND DEHUMIDIFICATION” on
page 42 of this document.
HORIZONTAL
CONVERSION KITS
RXGY-G02, RXGY-G03,
RXGY-G04 & RXGY-G05
Horizontal installation of the (-)GGD
modulating gas furnace is permitted
with the use of special kits available
from the manufacturer. The gas
valve must be mounted upright. This
is accomplished with a special manifold supplied with the conversion kit.
Assembly requires the removal of
the existing gas manifold and
replacing it with the one supplied in
the kit.
TABLE 13
AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (1 STAGE COOL ONLY)
MODEL
WIDTH
APPROX.
AIRFLOW
(CFM)
-GFD/GGD-06 & -07
-GFD/GGD-06 & -07*
-GFD/GGD-09 & -10*
-GFD/GGD-09 & -10*
-GFD/GGD-12
-GFD/GGD-12
17.5"
17.5"
21"
21"
24.5"
24.5"
800
1000
1200
1400
1200
1400
FURNACE
TONS
2
2-1/2
3
3-1/2
3
3-1/2
MOD. FURNACE IFC DIP-SWITCH SETTINGS
CONDENSING
UNIT
SW-1,#1
SW-1,#2
SW-1,#3
SW-1,#4
-ARA-24
-ARA-30
-ARA-36
-ARA-42
-ARA-36
-ARA-42
OFF
ON
ON
ON
ON
ON
ON
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.
(See condenser spec. sheet, I&O and other literature for evaporator selection)
TABLE 14
AIRFLOW AND CONDENSER SELECTION – PREMIUM COOLING SYSTEMS (2 STAGE COOL ONLY)
TONS
2
3
3
3
4
4
5
MODEL
WIDTH
APPROX.
AIRFLOW
(CFM)
-GFD/-GGD-06 & -07
-GFD/-GGD-06 & -07
-GFD/-GGD-09 & -10
-GFD/-GGD-12
-GFD/-GGD-09 & -10
-GFD/-GGD-12
-GFD/-GGD-12
17.5"
17.5"
21"
24.5"
21"
24.5"
24.5"
800
1200
1200
1200
1600
1600
1800
FURNACE
MOD. FURNACE IFC DIP-SWITCH SETTINGS
CONDENSING
UNIT
SW-1,#1
SW-1,#2
SW-1,#3
SW-1,#4
-ARL-24
-ARL-36
-ARL-36
-ARL-36
-ARL-48
-ARL-48
-ARL-60
OFF
OFF
ON
ON
ON
ON
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Evaporator coil must be the same width as the furnace OR one size larger in width than the gas furnace.
(See condenser spec. sheet, I&O and other literature for evaporator selection)
53
GENERAL
DIP SWITCH SET SW1
The UT Electronic Controls IFC board
(see Figure 41) is a recent addition to
the furnace and will be a direct replacement for all Johnson Controls IFC
boards. New features have been
added to the IFC board to improve airflow performance in the heating mode.
The new board also adds two-stage
capability in addition to the existing
modulating and single-stage operation.
Also, the locations of the original dip
switches (SW1 & SW2), and the location of the seven segment display are
different than the previous Johnson
Controls IFC board. The function of
these components has not changed.
For proper setting of the airflow switches
to meet requirements, see Figures 55
and 56.
➤ IMPORTANT: The dip switches on
SW2 (used for test mode and for operation with two-stage thermostats) must
be in the “OFF” position for modulating
or single-stage operation. If both
switches are in the “ON” position, a
missing “V” signal with a call on “W” will
cause the furnace to run only at 40%.
However, with both switches in the
“ON” position, the furnace will function
with a two-stage thermostat when connected as shown in Figure 44.
FIGURE 54
UT ELECTRONIC CONTROLS IFC BOARD
IMPORTANT: Do not attempt to install a
(-)GFD or (-)GGD modulating furnace
with a conventional, add-on zone system. System performance and occupant
comfort may be compromised.
➤ DIP SWITCH SET SW2
The UT Electronic Controls IFC board
has added two-stage capabilities. This
feature is activated by changing the
switches 1 & 2 of SW2 to the “ON” position and installing a two-stage thermostat as shown in Figure 44. This feature
allows the furnace to be used with a
standard two-stage thermostat. With
switches 1 & 2 of SW2 set to the “ON”
position, the furnace will go to 40% of
capacity when “W” is energized alone.
In this configuration, when “W” and “W2”
TABLE 15
SW2 MODE SELECTION SETTINGS
Mode
Switch 1 Position Switch 2 Position
Modulating/
Single-Stage
OFF
OFF
Test 40%
ON
OFF
Test 100%
OFF
ON
Two-Stage
ON
ON
are energized, the furnace runs at
65% for five minutes and then
changes to 100%. If the call for heat
ends at any time the furnace terminates immediately at the present firing rate.
DIP SWITCH SET SW3
The UT Electronic Controls IFC
board has an added set of dip
switches labeled SW3 (see Figure
53). The function of these dip switches is to fine-tune airflow in the heating mode. The dip switches will be
set to either the 40% or 100% (or
both) firing rate, and will adjust every
point in between accordingly.
SW3 will allow for airflow adjustments at high altitude, improper temperature probe locations, or no temperature probe applications. If temperature rise range is a problem, the
technician must use temperature
probes to determine the rise range
and adjust the airflow using SW3’s
dip switches until the temperature
rise is within the specified range.
ADJUSTING AIRFLOW
All airflow adjustments on SW3
should be made with the main power
OFF. Dip switches 1 through 3 will
adjust airflow at the 100% firing rate
and dip switches 4 through 6 will
adjust the airflow at the 40% firing
rate.
100% Firing Rate
To use SW3 to change the airflow at
the 100% rate:
1) Dip switch 1 must be “ON” (or
“ADJ”). This instructs the IFC that
the high firing rate airflow will be
overridden.
2) Dip switch 2 in the “OFF” position
will decrease airflow at 100% fire,
and in the “ON” position will
increase airflow at 100% fire.
3) If dip switch 3 is “OFF” the amount
airflow will be adjusted by 7.5%. If
it is “ON” amount of airflow will be
adjusted by 15%.
40% FIRING RATE
To use SW3 to change the airflow at
the 40% rate:
1) Dip switch 4 must be “ON” (or
“ADJ”). This instructs the IFC that
the high firing rate airflow will be
overridden.
2) Dip switch 5 in the “OFF” position
will decrease airflow at 40% fire,
and in the “ON” position will
increase airflow at 40% fire.
3) If dip switch 6 is “OFF” the amount
airflow will be adjusted by 7.5%. If
it is “ON” amount of airflow will be
adjusted by 15%.
54
FIGURE 55
AIRFLOW SWITCHES (SW1)
55
AIRFLOW ADJUSTMENT
EXAMPLES
Three examples of airflow adjustment
are shown below.
NOTE: All dip switches on SW3 will be
shipped in the “OFF” position.
Example 1
(see Figure 56)
PROBLEM: Temperature rise is too high
at 40% firing rate although it is within
the published range at 100% firing rate.
SOLUTION: More airflow is needed to
lower the temperature rise at 40%.
1) Set dip switches 4 and 5 of SW3 to
the “ON” position. This will produce a
7.5% increase in blower output.
2) Allow furnace to run for several minutes at 40% firing rate until temperature probes reach equilibrium.
3) If the temperature rise is still above
the published range, set switch 6 of
SW3 to the “ON” position. This will
increase the airflow rate from +7.5%
to +15% above the standard value.
EXAMPLE 2
EXAMPLE 3
(see Figure 57)
PROBLEM: Temperature rise is too low
at 100% firing rate although it is within
the published range at 40% firing rate.
SOLUTION: Less airflow is needed to
increase temperature rise at 100%.
1) Set dip switch 1 of SW3 to the “ON”
position, which overrides standard
airflow.
2) Leave switches 2 and 3 in the
“OFF” position to decrease airflow
by 7.5%.
3) Allow furnace to run for several
minutes at 100% rate until temperature probes reach equilibrium.
4) If the temperature rise is still below
the published range, set switch 3 to
the “ON” position. This will
decrease the airflow rate from 7.5% to -15% below the standard
value.
FIGURE 57
EXAMPLE 2
SW3
100%
ON
OFF
ADJ
--
5
+
6
--
2
+
3
15%
15%
5
+
6
15%
40%
SW3
--
+
15%
STD
ADJ
--
+
6
15%
15%
40%
ADJ
STD
5
+
100%
ON
OFF
4
ADJ
+
6
15%
6
7.5%
7.5%
5
--
+
4
STD
--
3
7.5%
ADJ
2
--
1
STD
ADJ
5
STD
15%
4
100%
OFF
ON
+
3
7.5%
ADJ
2
SW3
--
SW3
15%
7.5%
1
STD
EXAMPLE 3
3
100%
ON
OFF
A. Set switches 4 & 5 to “ON” position to
increase airflow by 7.5% at the 40%
fire rate.
SOLUTION: Less airflow is needed to
increase temperature rise at 40% firing rate and more is needed to
decrease temperature rise at 100%.
1) Set dip switch 4 of SW3 to the
“ON” position to override standard
airflow at 40% firing rate. Leave
switches 5 and 6 in “OFF” position
to decrease airflow by 7.5%.
3) If temperature rise is still lower
than the published range, set
switch 6 to the “ON” position to
decrease the airflow rate from
-7.5% to -15% below the standard
value.
4) Set dip switches 1 to the “ON”
position to override standard airflow at 100% firing rate. Set switch
2 to the “ON” position to increase
airflow by 7.5%.
6) If temperature rise is still higher
than the published range, set
switch 3 to “ON” position to
increase the airflow rate from 7.5%
to 15% above the standard value.
FIGURE 58
A. Set switch #1 to “ON” position and
leave #2 and #3 in the “OFF” position
to decrease airflow by 7.5% at the
100% fire rate.
40%
at 40% firing rate and is too high at
100%.
2
ADJ
7.5%
PROBLEM: Temperature rise is too low
1
4
7.5%
STD
4
1
ADJ
STD
--
3
100%
OFF
ON
STD
+
15%
7.5%
SW3
7.5%
--
2
EXAMPLE 1
ADJ
STD
1
FIGURE 56
(see Figure 58)
7.5%
40%
A. Set switch #4 to “ON” and leave #5
and #6 set to “OFF” to decrease airflow by 7.5% at the 40% fire rate. If
necessary, set switch #6 to “ON” to
decrease airflow by 15%.
B. If -7.5% is not enough, decrease
airflow by setting switch 3 to “ON”
position to give -15%.
SW3
100%
ON
OFF
--
2
+
3
15%
STD
4
ADJ
--
5
+
6
B. If +7.5% is not enough, increase airflow
by setting switch 6 to “ON” position to
give +15%.
ADJ
STD
1
40%
15%
7.5%
7.5%
40%
B. Set switches #1 and #2 to “ON” and
leave #3 set to “OFF” to increase
airflow by 7.5% at the 100% fire
rate. If necessary, set switch #3 to
“ON” to increase airflow by 15%.
56
START-UP PROCEDURES
FURNACE TEST MODE
FURNACE TEST SWITCHES
NOTE: The integrated furnace control
does not recognize switch setting
changes while energized. To change settings, remove power to the board, make
changes, then return power.
The Integrated Furnace Control is
equipped with three sets of field selectable switches. The set with five switches
(SW1) (See Figures 45 and 46) is for
selecting airflow operation options
(Airflow Switches). The set with two
switches (SW2) is for placing the furnace
into test mode for initial set-up and troubleshooting and for choosing between
modulating, single-stage and two-stage
functions. (see Figure 45).
The Test Switches will place the IFC into
a test mode, operating the furnace at
continuous input rates of either 100% of
full rate (maximum fire) or 40% of full
rate (minimum fire and 2-stage operation). This is accomplished by setting the
Test Switches as indicated in Table 16.
TABLE 16
SW2 MODE SELECTION SETTINGS
Mode
Modulating/
Single-Stage
Switch 1 Position Switch 2 Position
OFF
OFF
Test 40%
ON
OFF
Test 100%
OFF
ON
Two-Stage
ON
ON
To enter the Furnace Test Mode, proceed
as follows:
1. Switch the 115 volt power to the furnace OFF. Do not change settings
with control energized.
2. Position Test Switches 1 and 2 for
the desired test mode.
3. Switch the 115 volt power to the furnace ON.
4. Set the thermostat mode to HEAT,
adjust the setpoint at least 4°F above
room temperature to demand a call
for heating.
When the furnace is powered with the
test switches in a position other than
modulating/single-stage or in 2-stage
mode, the first call for heat within the
first hour after power-up will instruct the
furnace to perform as follows:
1. Normal ignition sequence
2. A calibration cycle will be performed
unless the Test Switches are set for
Test 40%. The LED status indicator
will flash “H” or “h” during the calibration cycle (see Table 18).
NOTE: The return air sensor (factory installed) and the supply air sensor (field installed) are required for
the furnace calibration cycle. If the
air sensors are faulty, or not properly connected, the furnace will not
attempt a calibration cycle and will
operate on factory default parameters pre-programmed into the microprocessor.
3. After calibration, the furnace will
then adjust to the desired Test
capacity. This allows time for the
technician to check steady-state
operation and evaluate furnace performance.
NOTE: Refer to Figure 54 (Furnace
Test Mode Sequence of Operation/
Troubleshooting), and Furnace
Performance Data Table 17.
4. The furnace will operate at the fixed
Test capacity until one of the following conditions:
a. The thermostat is satisfied and
the call for heat is removed.
b. The furnace has been in test
mode continuously for sixty minutes, at which time the controller
will go into modulating/singlestage operation.
NOTE: The IFC will only check the
test mode switches on power up.
Terminating the test mode by either
4a or 4b will place the furnace into
modulating or single-stage operation regardless of the test mode
switch positions.
To set the furnace for normal operation:
1. Set the thermostat mode to OFF.
Always allow furnace to complete
the cool down cycle.
2. Switch the 115 volt power to the
furnace OFF. Do not change
settings with control energized.
3. Position Test Switches 1 and 2 for
modulating/single-stage mode or
2-stage mode.
4. Switch the 115 volt power to the
furnace ON.
5. Set the thermostat as desired.
THERMOSTAT TEST
MODE
SEE THERMOSTAT SECTION OF
THESE INSTRUCTIONS FOR TESTMODE DIRECTIONS.
TO START THE FURNACE
control access door.
2. IMPORTANT: Be sure that the
manual gas control has been in
the “OFF” position for at least
five minutes. Do not attempt to
manually light the main burners.
3. Set the room thermostat to its
lowest setting and turn off the
furnace electrical power.
4. Turn the gas control knob to the
“ON” position.
5. Replace the burner compartment
!
WARNING
FAILURE TO REPLACE THE
BURNER DOOR CAN CAUSE
PRODUCTS OF COMBUSTION
TO BE RELEASED INTO THE
CONDITIONED AREA RESULTING IN PERSONAL INJURY OR
DEATH.
6. Turn on the furnace electrical
power.
7. Set the room thermostat at least
4° F above room temperature to
light the main burners.
8. After the burners are lit, set the
room thermostat to a desired
temperature.
57
TABLE 17
FURNACE PERFORMANCE DATA
Operating
Level
Inducer
Speed
Servo Valve
Current
100%
High
~180 milliamps
90%
High
~162 milliamps
80%
High
~144 milliamps
70%
High
~126 milliamps
60%
High
~108 milliamps
50%
High
~90 milliamps
40%
Low
~72 milliamps
Calibration
High
~135 milliamps
Manifold Pressure
Natural - 3.5" w.c. (±0.3")
LP - 10.0" w.c. (±0.5")
Natural - 2.8" w.c. (±0.3")
LP - 8.1" w.c. (±0.5")
Natural - 2.2" w.c. (± 0.3")
LP - 6.4" w.c. (± 0.5")
Natural - 1.7" w.c. (±0.3")
LP - 4.9" w.c. (± 0.5")
Natural - 1.3" w.c. (± 0.3")
LP - 3.6" w.c. (± 0.5")
Natural - 0.9" w.c. (± 0.3")
LP - 2.5" w.c. (± 0.5")
Natural - 0.6" w.c. (± 0.3")
LP - 1.6" w.c. (± 0.5")
Natural - 2.0" w.c. (± 0.3")
LP - 5.6" w.c. (± 0.5")
Temperature
Rise
40°-70° F
40°-70° F
40°-70°F
40°-70°F
40°-70°F
40°-70°F
40°-70°F
40°-70°F
NOTE: Gas valve milliamp readings may vary ± 05%.
TABLE 18
NORMAL OPERATION INDICATORS - DIAGNOSTIC LED
LED
SYMBOL
DESCRIPTION
COMMENTS
All symbols indicate furnace control board is properly
powered.
O
System OFF
There is no demand from the thermostat. There
are no active faults.
System FAN ONLY
The IFC is receiving 24V on the “G”
terminal ONLY. There are no active faults.
C
System COOL
The IFC is receiving 24 V on the “YL”
and/or “YH” terminals. There are no active faults.
H
System HEAT
The IFC is receiving 24 V on the “W”
terminal. The modulating signal is present on the
“V” terminal. There are no active faults.
h
System HEAT
terminal. The modulating signal is NOT present on
the “V” terminal. There are no active faults.
“H”
Flashing
Calibration Cycle
terminal. The modulating signal is present on the
“V” terminal. The furnace is in calibration mode.
There are no active faults.
“h”
Flashing
Calibration Cycle
terminal. The modulating signal is NOT present on
the “V” terminal. The furnace is in calibration
mode. There are no active faults.
F
58
TO SHUT DOWN
THE FURNACE
1. Set the room thermostat to its lowest setting.
3. Shut off the gas to the main burners
by turning the gas control knob to
the “OFF” position.
4. Replace the burner compartment
!
WARNING
SHOULD OVERHEATING OCCUR
OR THE GAS SUPPLY FAIL TO
SHUT OFF, CLOSE THE MANUAL GAS VALVE FOR THE APPLIANCE BEFORE SHUTTING OFF
THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN CAUSE AN
EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE,
SEQUENCE OF OPERATION
Heating Cycle Initiation
The heating cycle is always initiated by
a 24 volt signal on W of the thermostat.
When the controller senses 24 volts on
W, the following sequence occurs:
• High and low pressure switches are
checked to insure contacts are open.
• Inducer is powered on high speed for
a thirty (30) second prepurge.
• Pressure switches are monitored as
the inducer creates the vacuum to
close the contacts.
• The servo valve on the gas valve is
energized with ~180 milliamps current.
(No flow yet.)
• The controller sends 120 volts to the
ignition control, which sparks across
the electrodes.
• The main solenoids on the gas valve
are energized allowing gas to flow to
the burners.
• When flame is proven, the ignition
control is de-energized - 8 second
maximum trial time.
• The gas valve maintains 100% rate
through the warm-up period - 20 seconds.
Heating Cycle Response
The heating cycle is always initiated by a
24 volt signal on W1. When the controller
senses 24 volts on W1, the following
sequence occurs:
MODULATING FUNCTION:
(“W” and “V” signal inputs, refer to dip
switch set SW2 on IFC)
After the warm-up period, the furnace
will respond to the thermostat demand
by adjusting the gas valve pressure
and blower speed anywhere between
40% to 100% heating capacity.
TABLE 19
METER TIME
METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES
EQUIPPED FOR NATURAL OR LP GAS
HEATING VALUE OF GAS BTU PER CU. FT.
INPUT
BTU/HR
60,000
75,000
90,000
105,000
120,000
METER
SIZE
CU. FT.
900
1000
1040
1100
2500 (LP)
MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.
ONE
0
54
1
0
1
3
1
6
2
TEN
9
0
10
0
10
24
11
0
25
30
0
ONE
0
44
0
48
0
50
0
53
2
0
TEN
7
12
8
0
8
19
8
48
20
0
ONE
0
36
0
40
0
42
0
44
1
40
TEN
6
0
6
40
7
0
7
20
16
40
ONE
0
31
0
34
0
36
0
38
1
26
TEN
5
10
5
40
6
0
6
20
14
20
ONE
0
27
0
30
0
31
0
33
1
15
TEN
4
30
5
0
5
10
5
30
12
30
DRY Heating Value of Gas (BTU/FT3) x 3600
Formula: Input BTU/HR =
xC•F
Time in Seconds (for 1 cu. ft.) of Gas
Where C • F =
Gas Pressure (inch • Hg) x 520 (˚F)
Gas Temperature (˚F) x 30 (inches • Hg)
➤ TWO-STAGE FUNCTION:
(Two-stage function only applies when
both switches of SW2 are in the “ON”
position and a two-stage thermostat is
installed as shown in Figure 30.)
by adjusting the gas valve pressure and
blower heating speeds to the “W” signal
values. “W” only = 40% gas valve pressure and blower heating speed. “W2” =
65% gas valve pressure and blower
heating speed for first five minutes and
100% thereafter. Also, if the call for heat
ends, the furnace terminates at the present rate.
➤ SINGLE-STAGE FUNCTION:
(“W” signal only)
by altering the gas valve pressure and
blower speed as follows:
Phase 1: 0 to 5 minutes = 40% of furnace
capacity (gas valve output and blower
speed)
Phase 2: 5 to 12 minutes = 65% of furnace capacity (gas valve output and
blower speed)
Phase 3: After 12 minutes = 100% of furnace capacity (gas valve output and
blower speed)
NOTE: If the call for heat ends during any
phase, the furnace will terminate immediately at the firing rate of that phase.
Heating Cycle Termination
(“W” signal only, refer to dip switch set
SW2 on IFC)
When the 24 volt signal is removed from
W1, the heating cycle will end and the furnace will shut down and return to the
proper off cycle operation.
SETTING INPUT RATE
Checking furnace input is important
to prevent over firing beyond its
design-rated input. NEVER SET
INPUT ABOVE THAT SHOWN ON
THE RATING PLATE. Use the following table or formula to determine
input rate. Prior to checking the furnace input, make certain that all
other gas appliances are shut off,
with the exception of pilot burners.
Time the meter with only the furnace
in operation. Start the furnace, in
Furnace Test Mode, 100% rate, and
measure the time required to burn
one cubic foot of gas.
The furnace is shipped from the factory with #50 orifices. They are sized
for natural gas having a heating
value of 1075 BTU/cu. ft. and a specific gravity of .60. For high-altitude
models (option 278) the furnace
comes equipped with #51 orifices
installed for elevations above 5,000
ft. These orifices may still need to be
changed based on both elevation
and gas heating value. Consult the
section of this book titled “High
Altitude Installation” for details.
Since heating values vary geographically, the manifold pressure and/or
gas orifice size may need to be
changed to adjust the furnace to its
nameplate input. The rate will also
vary with altitude. Consult the local
gas utility to obtain the yearly average heating value and orifice size
required to fire each individual burner
at 15,000 BTUH. For high altitude
installations, also consult the section
of this manual titled “High Altitude
Installations” for details on how to
calculate the correct orifice size.
59
MAINTENANCE
!
WARNING
DISCONNECT MAIN ELECTRICAL
POWER TO THE UNIT BEFORE
ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN
CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL
INJURY OR DEATH.
TABLE 20
FILTER SIZES
UPFLOW FILTER SIZES
FURNACE
WIDTH
INPUT
KBTUH
BOTTOM
SIZE
SIDE
SIZE
171/2"
60 AND 75
21"
241/2"
90 AND 105
153/4" X 25"
191/4" X 25"
223/4" X 25"
153/4" X 25"
153/4" X 25"
153/4" X 25"
120
QUANTITY
1
1
1
FILTERS
Keep the filters clean at all times.
Remove the filter. Vacuum dirt from filter,
wash with detergent and water, air dry
thoroughly and reinstall.
FIGURE 60
RESIZING FILTERS AND FRAME
NOTE: Some filters must be resized to fit
certain units and applications. See Table
14 and Figures 59, 60, 61 and 62.
1. 21" - 90,000 & 105,000 BTUH units
require removal of a 31/2-in. segment
of filter and frame to get the proper
width for a side filter.
2. 241/2" - 120,000 BTUH unit requires
removal of a 7" segment of filter and
frame to get the proper width for a
side filter.
REMOVE SEGMENT TO SIZE
AS REQUIRED
2409401
FIGURE 59
UPFLOW — FILTER REPLACEMENT
542201
60
FIGURE 61
UPFLOW -- SIDE FILTER LOCATIONS
CUT-OUT AND DRILL DETAIL
ROD & FILTER SUPPORT ANGLE ASSEMBLY
FIGURE 62
FIGURE 63
DOWNFLOW -- FILTER INSTALLATION
HORIZONTAL -- FILTER INSTALLATION
1332
A087001.S01
A087101.S01
61
!
CAUTION
DO NOT OPERATE THE SYSTEM
FOR EXTENDED PERIODS WITHOUT FILTERS. A PORTION OF
THE DUST ENTRAINED IN THE
AIR MAY TEMPORARILY LODGE
IN THE AIR DUCT RUNS AND AT
THE SUPPLY REGISTERS. ANY
RECIRCULATED DUST PARTICLES WILL BE HEATED AND
CHARRED BY CONTACT WITH
THE FURNACE HEAT EXCHANGER. THIS RESIDUE WILL SOIL
CEILINGS, WALLS, DRAPES,
CARPETS AND OTHER HOUSEHOLD ARTICLES.
LUBRICATION
IMPORTANT: Do Not attempt to lubricate the bearings on the blower motor or
the induced draft blower motor. Addition
of lubricants can reduce the motor life
and void the warranty.
The blower motor and induced draft
blower motor bearings are prelubricated
by the manufacturer and do not require
further attention.
blower motor must be cleaned periodically by a qualified installer, service
agency, or the gas supplier to prevent
the possibility of overheating due to an
accumulation of dust and dirt on the
windings or on the motor exterior. The
air filters should be kept clean. As dirty
filters can restrict airflow. The motor
depends upon sufficient airflowing
across and through it to keep from overheating.
SYSTEM OPERATION
INFORMATION
4. Avoid excessive use of kitchen
exhaust fans.
5. Do not permit the heat generated
by television, lamps or radios to
influence the thermostat operation.
6. Explain proper operation of the
system with constant air circulation.
ANNUAL INSPECTION
The furnace should operate for many
years without excessive scale build-up
in the flue passageways. However, it is
recommended that a qualified installer,
service agency, or the gas supplier
annually inspect the flue passageways,
the vent system and the main burners
for continued safe operation. Pay particular attention to deterioration from corrosion or other sources.
During the annual inspection, all electrical power to the furnace should be
turned off and then restored. This will
put the furnace into a calibration cycle
on the initial call for heat. This is a five
minute (or until the heat call is satisfied)
cycle which allows the furnace to evaluate conditions It should be noted, that
a calibration cycle will occur on the initial call for heat each time after line voltage has been interrupted to the unit.
IMPORTANT: It is recommended that at
the beginning and at approximately half
way through the heating season, a visual inspection be made of the main burner flames for the desired flame appearance by a qualified installer, service
agency or the gas supplier. If the flames
are distorted and/or there is evidence of
back pressure, check the vent and inlet
air system for blockage. If there is carbon and scale in the heat exchanger
tubes, the heat exchanger assembly
should be replaced.
Advise The Customer
IMPORTANT: Replace all blower doors
and compartment covers after servicing
the furnace. Do not operate the unit
without all panels and doors securely in
place.
1. Keep the air filters clean. The heating system will operate more efficiently and more economically.
2. Arrange the furniture and drapes so
that the supply air registers and the
return air grilles are unobstructed.
3. Close doors and windows. This will
reduce the heating load on the system.
62
!
WARNING
HOLES IN THE VENT PIPE OR HEAT
EXCHANGER CAN CAUSE TOXIC
FUMES TO ENTER THE HOME,
RESULTING IN CARBON MONOXIDE
POISONING OR DEATH. THE VENT
PIPE OR HEAT EXCHANGER MUST
BE REPLACED IF THEY LEAK.
IMPORTANT: It is recommended that
at the beginning of the heating season, the flame sensor be cleaned with
steel wool by a qualified installer, service agency or the gas supplier.
at the beginning of the heating season, the condensate trap be inspected for debris or blockage. A blocked
condensate trap can cause water to
back up into the primary heat
exchanger and lead to nuisance tripping of the over temperature switches
and/or pressure switches.
at the beginning of the heating season, the condensate neutralizer if
used be replaced by a qualified
installer, service agency or the gas
supplier.
an annual inspection and cleaning of
all furnace markings be made to
assure legibility. Attach a replacement
marking, which can be obtained
through the distributor, if any are
found to be ILlegible or missing.
REPLACEMENT PARTS
Contact your local distributor for a
complete parts list.
TROUBLESHOOTING
Figure 64 is a troubleshooting flowcharts for the sequence of operation.
Table 21 is for fault-code descriptions.
WIRING DIAGRAM
Figure 65 is a complete wiring diagram for the furnace and power
sources.
FIGURE 64
SEQUENCE OF OPERATION TROUBLESHOOTING FLOWCHART
Start
1. De-energize furnace IFC
2. Set test switches (SW2) to
desired setting: 100% or 40%
3. Re-energize furnace IFC
4. Set thermostat to heat, set 4°
above room temperature
LED status display is blank
LED status display shows "H"or “h”
no
yes
1. Check transformer secondary voltage
2. Check line voltage
3. Check transformer secondary fuse
If 1, 2, and 3 check OK, replace IFC
LED status display shows "0", "C", or "F"
1. Call for heat at the thermostat, cycle furnace power, go to
"start"
LED status display shows numeric function code
1. See function code troubleshooting guide
Induced draft motor (IDM) starts
on high speed for 30 second
prepurge
Motor does not start
no
yes
1. Check status display - FUNCTION CODE 44 or 55, Check
pressure switches. FUNCTION CODE 45 or 57, Check IDM
2. Check voltage to IDM high speed tap
3. Check IDM run capacitor
If 2 & 3 check OK, replace IDM assembly
4. Check wiring
5. Check voltage on IDM pin on IFC
If 5 checks bad, replace IFC
Motor runs for 60 seconds, then cycle terminates
1. Check status display - FUNCTION CODE 45 or 57 expected,
see function code troubleshooting guide
Motor starts on low speed
1. Check wiring
Gas valve servo valve set to
100% rate (~180 milliamps D.C.)
Servo current measures less than 170 milliamps D.C.
no
yes
1. Check status display - possible codes 77 or 78, see function
code troubleshooting guide
No spark present at igniter
Direct spark igniter is activated
(8 second trial for ignition)
yes
1. Check status display - FUNCTION CODE 45 or 57 expected
no
2. Check pressure switches
3. Check 120 volts to igniter control during trial for ignition (30
seconds after IDM starts). If 3 checks OK, go to step 6. If
120 volts not present, then
4. Check wiring
5. Check 120 volts on IFC spark igniter pins, if bad replace IFC
continued on next page
6. Check spark wire connection
7. Check spark wire & electrode ceramic
8. Check spark gap (0.10 inches), if 6, 7, and 8 check OK
replace spark control
63
Burners light
no
yes
Ignition trial duration is 8 seconds. The gas valve will be energized (24 volts between M/P & C) for this period and will remain
energized only if the flame sense signal is above a minimum
threshold by this time. If the first trial is not successful, three additional trials will be made with IDM purge periods of 30 seconds at
high speed between retries.
If the burners do not light:
1. Check status display - FUNCTION CODE 11 expected
2. Check for 24 volts between "M/P" and "C" - if 24 volts not
present, go to step 5
3. Check gas line inlet pressure
4. Check manifold pressure - if steps 2 & 3 are OK, but 4 is bad
- replace gas valve
5. Check wiring
6. Check for 24 volts on the IFC valve pins - if 6 checks bad replace IFC
7. Check spark electrode position
Burners remain lit beyond 8 second trial time
Failure to sense flame:
no
yes
Indoor blower motor starts 20
seconds after gas valve opens
1. Check status display - FUNCTION CODE 11 expected - see
function code troubleshooting guide
Motor does not start:
no
1. Check status display -FUNCTION CODE 67 or 68 expected
2. Check for 120 volts to motor (5 pin plug)
yes
3. Check wiring
4. Test motor with ECM2+ motor tester (see ECM2+ motor test
procedures)
If 2, 3, and 4 test OK, replace IFC
If furnace test switches are set
to 100%, calibration cycle executes and status display blinks
"H" or ''h''. Duration is 5 minutes.
Calibration is performed with the
furnace operating at 75% capacity. The inducer will run on high
speed, the servo valve current
will be set at about 135 milliamps resulting in a manifold
pressure of around 2.0" w.c. Nat.
(5.6" w.c. L.P.)
yes
continued on next page
64
Supply air sensor faulty or not installed
no
2. Ensure supply air sensor is installed in the plenum and is
properly wired to the IFC
3. Check resistance of supply air sensor - if step 3 checks bad,
replace sensor
Return air sensor faulty or not installed
2. Check return air sensor wiring
3. Check resistance of return air sensor - if step 3 checks bad,
replace sensor
FURNACE TEST SWITCHES SET
AT 100 %
Furnace runs at 100% rate, status
display shows "H" or “h”, inducer
on high speed, servo current is
~180 milliamps, manifold pressure
is ~3.5 " w.c. and temperature rise
is 40 - 70 ºF
no
Monitor status display for abnormal indications, see function code
troubleshooting guide
no
Monitor status display for abnormal indications, see function code
troubleshooting guide
FURNACE TEST SWITCHES SET
AT 40 %
Furnace runs at 40% rate, status
display shows "H" or “h”, inducer on
low speed, servo current is ~ 72
milliamps, manifold pressure is
~0.6 " w.c. and temperature rise is
40 - 70°F
Terminate test mode
yes
1. Test mode times out in 60
minutes.
2. Remove the call for heat
from the W terminal
Status display shows "C", "F", or "H"
yes
LED status display shows "O" gas
valve off, flames off
1. Ensure thermostat is off
2. Check thermostat wiring
no
Flames remain on
1. Check 24 volts to gas valve solenoids (M/P) - if present, go to
step 2, if 24 volts is not present, shut off gas and replace the
gas valve
yes
2. Check wiring
3. Check 24 volts on IFC valve pins (MV) - if status display
shows "O" and 24 volts is present in step 3, replace IFC
Induced draft motor stops after 20
5
seconds
Induced draft motor doesn't stop
no
yes
1. Check status display - FUNCTION CODE 22 or 33 expected
2. Check over-temperature switch(es)
3. Check wiring
If steps 2 & 3 check OK, replace IFC
ECM2+ indoor blower motor stops
after 90 seconds
ECM2+ indoor blower motor does not stop running
no
yes
1. Check status display - FUNCTION CODE 22, 23 or 33 expected
2. Check main limit and over temperature switch(es)
3. Test motor with ECM2+ motor tester (see ECM2+ motor test
procedures)
If steps 2 & 3 check OK, replace IFC
Troubleshooting ends
To return system to modulating/single-stage operation (SW2):
1. De-energize IFC
2. Set furnace test switches (SW2) for desired operation
REPEAT PROCEDURE UNTIL TROUBLEFREE OPERATION IS OBTAINED IN
100% AND 40% TEST MODES
3. Re-energize IFC
4. Set thermostat for desired operation
65
66
One-Hour Retry
Internal fault
Failed Ignition Trial
Low Flame Sense
–
11
12
Description
r
Function Code
Flame sense level is below
predetermined threshold but
above minimum operating threshold. Remains displayed until flame
sense level rises above threshold
level or heat demand is removed.
Fault is stored in buffer after four
consecutive failed ignition trials in
a single heat call
No flame sense during ignition trial.
Remains displayed until successful
ignition, one hour retry is started or
heat demand is removed
Failed microprocessor self test or
main gas valve safety circuit fault.
Hard lockout
A furnace fault has caused the
controller to execute a one-hour
retry mode.
Response Comments
Solutions
B. Flame Sensor improperly mounted or
grounded
1. Re-install / replace flame sensor, check
wiring and connections.
1. Clean flame sensor rod
F. Burners light, but extinguish after 8
seconds or less
A. Flame sensor contaminated
1. Check for proper polarity of line voltage.
2. Check flame sensor wiring and connections.
3. Check for improperly mounted flame
sensor (positioned out of flame,
grounded).
4. Check flame sense current.
5. Clean flame sensor rod.
C. Insufficient manifold pressure, gas
valve “ON”
1. Check for proper mounting and placement spark electrode assembly.
2. Check for proper mounting of burner
assembly.
1. Check 24 VAC to gas valve.
2. Check for 170 - 190 mAmps to servo
valve.
3. Adjust valve for proper manifold pressure at 100% rate
4. If gas valve will not adjust, replace gas
valve.
E. Burners don’t light
1. Turn gas valve to the “ON” position
B. Gas valve control turned “OFF”
D. No spark at electrodes
1. Insure gas supply is connected to furnace and check for proper line pressure
A. Insufficient line gas pressure
1. Check 120 VAC at igniter control during
ignition trial.
2. Check spark wire connection at igniter
control transformer and electrode.
3. Check for short to ground of electrode
(cracked ceramic, touching burners, etc.)
4. Check igniter wire for damage.
5. If all checks OK, replace igniter control
1. Check for mis-wiring in furnace
2. Replace IFC
1. Check for function code 11 in buffer.
See solutions for function code 11.
2. Check for function code 13 in buffer.
See solutions for function code 13.
A. Voltage sensed on the MV output
B. Software Self-test output
A. Failed ignition trial four times (code 11)
B. Lost flame sense four times (code 13)
Probable Causes
FAULT CODE TROUBLESHOOTING CHART
TABLE 21
High limit circuit is open. Remains
displayed until circuit is sensed
closed.
Auxiliary limit circuit is open.
Remains displayed until circuit is
sensed closed.
Lost Flame Sense
Improper Flame Sense
High Limit
Auxiliary Limit
(HALC)
13
14
22
23
Flame sensed when gas valve is off.
Remains displayed until flame
sense
signal is gone.
Fault is stored in buffer after four
ignition retries in a single heat call.
Flame sense is below minimum
operating threshold during a heating
cycle. Remains until a successful
ignition sequence, one hour retry is
started or the heat demand is
removed.
Response Comments
Description
Function Code
1. Repair jumper between pins 5 & 11
on J1.
A. On upflow furnaces jumper loose,
broken or missing
C. On downflow furnaces, no airflow
1. Check Fault Buffer for ECM motor fault
history
2. Check ECM motor wiring to the control
board.
3. Test ECM motor and replace if faulty.
1. Replace Limit.
1. Insure properly sized orifices installed.
2. Check manifold pressure and adjust as
needed.
D. Input rate too high.
B. On downflow furnace, faulty HALC.
1. Replace limit control
C. Faulty limit control
B. Insufficient airflow
A. No airflow
1. Replace IFC board
B. Flame goes out in “OFF” cycle
1. Check Fault Buffer for ECM motor
fault
history
2. Check ECM motor wiring to the control board.
3. Test ECM motor and replace if faulty.
1. Check Fault Buffer for ECM motor
fault history
2. Check filters and duct work for restrictions
3. Check rate and outlet air temperature
at 100%, and 40%, compare to maximum on nameplate
4. Run furnace calibration and re–check
outlet air temperature
1. Repair mis-wiring to remove continuous 24V to valve.
2. Gas valve stuck open - remove and
replace.
A. Flame remains lit in “OFF” cycle
C. Unstable flame pattern
1. Check that all burner assembly components are properly installed.
2. Check that all seals between the
vestibule area and the heat exchanger
area are tight
3. Insure that the combustion door gasket
is in place and the door is properly
installed.
1. Re-install / replace flame sensor, check
wiring and connections.
1. Clean flame sensor rod
A. Flame sensor contaminated
B. Flame sensor improperly mounted or
grounded
Solutions
Probable Causes
TABLE 21
FAULT CODE TROUBLESHOOTING CHART, CONT.
67
Description
Over–Temperature Limit
LPS –Contacts Closed
LPS – Open – IDM=HI
Function Code
33
68
44
45
Low pressure switch circuit is open
during high speed IDM operation.
Remains displayed until a successful ignition sequence or the heat
demand is removed
Low pressure switch circuit is
closed when no call for heat.
Remains displayed until circuit
opens or heat demand is removed.
Over–temperature limit circuit is
open. Remains displayed until circuit is sensed closed.
Response Comments
C. Improper pressure switch setting
B. Insufficient combustion air
1. Replace Low Pressure Switch
1. Check for leaking hoses or leaking
gasket at the induced draft blower
1. Check for proper venting and termination as defined in the furnace installation instructions
C. Abnormally high negative pressure
present on vent system
A. Insufficient combustion airflow
1. Replace low pressure switch
B. Faulty switch
1. Check for shorted wires to the low
pressure switch
A. Faulty wiring
B. Insufficient combustion air
C. Unstable flame pattern
1. Check that inducer is operating at
proper speed and RPM.
2. Insure venting does not exceed the
maximum lengths specified in the
venting instructions.
3. Check that all gaskets between the
inducer and the center panel / heat
exchanger are properly installed and
no leaks exist
1. Check that all burner assembly components are properly installed.
2. Check that all seals between the burner
compartment and the heat exchanger
area are tight.
3. Insure that the door seals are in place
and the door is properly installed.
4. Check that the heat exchanger has not
been damaged; ie. crushed tubes,
breached collector boxes
1. Replace limit control.
Solutions
A. Faulty limit control
Probable Causes
TABLE 21
Low pressure switch circuit is open
during low speed IDM operation.
demand is removed
Auxiliary Limit
LPS - Open - IDM = LO
HPS – Contacts Closed
HPS - Closed - IDM = LO
HPS – Open – IDM=HI
46
55
56
57
High pressure switch circuit is open
during high speed IDM operation.
demand is removed.
Remains displayed until heat
demand is removed
High pressure switch circuit is
closed during low speed IDM operation.
High pressure switch circuit is
closed with no call for heat.
Remains displayed until circuit
opens or heat demand is removed.
Response Comments
Description
Function Code
1. Insure vent system has minimum recommended vent lengths.
2. Insure vent system is properly terminated.
3. Insure combustion compartment door is
properly installed.
A. Minimum vent requirements not followed
1. Replace High Pressure Switch
1. Replace High Pressure Switch
E. Faulty switch
1. Check that the maximum vent length
for the application has not been
exceeded and that the vent is properly
terminated
2. Check that the combustion air inlet
and vent pipes are not restricted
3. Check that the induced draft motor is
operating at the proper speed.
1. Check drain lines for blockage, kinks
or double traps
2. Insure drain trap has been filled with
water before operation
D. Improper pressure switch setting
C. Insufficient pressure sensed at switch
B. Condensate not draining from heat
exchanger
B. Improper switch setting
1. Replace high pressure switch
B.Faulty switch
1. If high altitude pressure switch is
installed and installation site elevation is
near 5,000 feet, check cold pressures on
high speed inducer to insure pressure
switch change was necessary.
2. Replace high pressure switch as needed.
1. Check that the wires to the high pressure switch have not been shorted
together
E. Faulty switch
A. Faulty wiring
1. Check that the maximum vent length for
the application has not been exceeded
and that the vent is properly terminated
2. Check that the combustion air inlet and
vent pipes are not restricted
3. Check that the induced draft motor is
operating at the proper speed.
1. Check drain lines for blockage, kinks
or double traps
2. Insure drain trap has been filled with
water before operation
Solutions
D. Improper pressure switch setting
C. Insufficient pressure sensed at switch
B. Condensate not draining from heat
exchanger
Probable Causes
TABLE 21
69
70
ECM – RPM Range
ECM – Improper Signal
ECM – No Signal
GV Servo – Open
GV Servo – Control Fault
RAS / SAS – Out of Range
67
68
77
78
81/82
Description
66
Function Code
B. Unit installed in a “normal extreme”
installation (see solution #5)
A. ECM motor operating at RPM limit.
Probable Causes
Return / Supply air sensor out of
range. Remains displayed for 1.5
minutes after power on. After that
time codes remain in memory but
are not displayed. Recycling the
power will redisplay codes.
Gas valve current sensing circuit
tests out of range. Remains displayed until circuit tests OK or heat
demand is removed.
Gas valve servo circuit is sensed
open. Remains displayed until circuit is closed or heat demand is
removed.
ECM feedback signal missing.
Remains displayed until feedback is
corrected or blower operation
requirement is
removed.
1. Check resistance of thermistor.
Replace sensor if out of tolerance
2. Reconnect sensor if used. If not used,
then furnace is operating normally.
C. Sensor Not Connected or not used
1. Ensure continuity from board connector
to gas valve and to ground, check all
connections
B. Faulty Thermistor Assembly
A. Faulty wiring
A. Gas valve servo coil out of specification
1. Conduct the following test:
a. Turn the gas valve control knob to
the off position.
b. Disconnect servo valve connector
and place a 100-Ohm, 10-Watt
resistor across the two wires from
the furnace wiring harness (not the
wires from the gas valve).
c. Set the furnace to attempt another
ignition cycle.
d. If Function code 78 appears, replace
the IFC.
e. If Function code 11 appears, replace
the gas valve
1. Replace control board if faulty.
C. Faulty control board
1. Ensure continuity from board connector to gas valve and to ground, check
all connections.
A. Faulty wiring
1. Check resistance of servo–valve coil.
Replace valve if out of tolerance.
1. Replace control board if necessary
C. Faulty control board
B. Faulty gas valve
1. Test motor for feedback signal, replace
motor if faulty.
1. Ensure the ECM wiring harness is
complete and connected
2. Test motor feedback signal, replace if
faulty
Check for dirty filter
Check for inadequate return air supply
Check for under–sized duct work
Check for loose blower wheel
Unit installation is at environmental limits of: altitude, system static pressures,
high efficiency air filters, etc. Blower
demand requires operation at RPM limit.
1. Check motor part number, replace
motor if needed.
1.
2.
3.
4.
5.
Solutions
B. Faulty ECM motor
A. Faulty wiring
ECM Feedback signal does not follow
defined protocol – RPM / CFM blink.
Remains displayed until feedback is A. Wrong ECM motor installed
corrected or blower operation
requirement is removed.
ECM feedback signal indicated the
indoor blower motor RPM is above
1200. Remains displayed until RPM
returns to normal operating range or
blower operation requirement is
removed.
Response Comments
TABLE 21
FIGURE 65
WIRING DIAGRAM
71
72
CM 1204
SECTION 2
THERMOSTAT INSTRUCTIONS
PROGRAMMABLE MODULATING THERMOSTAT
(PART # 41-24312-04)
NON-PROGRAMMABLE THERMOSTAT
(PART #41-25347-01)
!
RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!
!
WARNING
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO
QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER
INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT.
READ THESE INSTRUCTIONS THOROUGHLY BEFORE
ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER
INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE
POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
DO NOT DESTROY THIS MANUAL
PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN
92-24321-05-02
SUPERCEDES 92-24321-05-01
INSTALLING YOUR THERMOSTAT
! WARNING
SHOCK HAZARD
Disconnect the power supply
before any wiring connections or
changes are made to prevent
electrical shock or possible
damage to the equipment. Follow
all local electrical codes during
installation. All wiring must
conform to local and national
electrical codes. Improper wiring
or installation may damage this
product, electrical shock,
property damage or death.
! CAUTION
EQUIPMENT DAMAGE HAZARD
Before connecting the power
supply to finished installation,
make all wiring connections and
VERIFY all connections. Shortcircuited or improperly
connected wires will result in
permanent damage to the unit
INTRODUCTION
LOCATION
This thermostat is an electronic
24-VAC, wall-mounted thermostat. It
uses two set points to maintain and
control room temperature in both the
heating and cooling modes. No
batteries are required: temperature,
fan, mode, and installer configuration
settings are preserved if there is a
loss of power.
The most important consideration in
installing your electronic thermostat
is where to locate the unit. The
location can radically affect the
operation of the thermostat. To
ensure proper operation, the
thermostat should be mounted on an
inside wall, in a frequently occupied
area of the building. In addition, its
position must be at least 18 inches
(46cm) from any outside wall, and
approximately 5 feet (1.5m) above
the floor in a location with freely
circulating air of an average
temperature.
IMPORTANT: THE 41-24312-04
THERMOSTAT REPLACES ALL
PAST THERMOSTATS WITH PART
NUMBERS 41-24312-02 AND 4124312-03 THAT ARE NO LONGER
AVAILABLE.
THIS THERMOSTAT IS INTENDED
FOR USE WITH THE MODULATING
HEAT 90 PLUS GAS FURNACE.
THIS THERMOSTAT CANNOT BE
USED IN HEAT PUMP
APPLICATIONS.
INSTALLATION
CONSIDERATIONS
You should prepare ahead if you are
installing any of the options
mentioned in other sections of this
manual.
If this is a new installation or a
replacement, verify:
• the size of wire needed or installed
• length of wire needed (distance
from the thermostat and the
equipment, and optional
equipment)
• if installing any remote
temperature sensing equipment
(please read the installation
instructions packaged with these
units before proceeding any
further)
The thermostat is to be connected
using unshielded (18 AWG minimum)
thermostat wire.
2
BE SURE TO AVOID THE
FOLLOWING LOCATIONS:
• behind doors or in corners where
freely circulating air is unavailable
• where direct sunlight or radiant
heat from appliances might affect
control operation
• on an outside wall
• adjacent to, or in line with,
conditioned air discharge grills,
stairwells, or outside doors
• where its operation may be
affected by steam or water pipes
or warm air stacks in an adjacent
partition space, or by an area not
heated or cooled behind the
thermostat
• where its operation will be affected
by the supply air of an adjacent
unit
• near sources of electrical
interference such as arcing relay
contacts
THERMOSTAT
INSTALLATION
FIGURE 1
THERMOSTAT SUBBASE
WIRE OPENING
IMPORTANT: WHEN REPLACING AN
EXISTING THERMOSTAT, USE WIRE
TAGS TO IDENTIFY TERMINAL
DESIGNATIONS AS YOU
DISCONNECT THE UNIT.
WIRE TERMINALS
NOTE: Before you start, you will need
the following supplies:
• Drill
• 3/16 inch (4.7mm) drill bit
• 1/8 inch (3mm) flat blade screwdriver
• Hammer
• Marking pencil
• Wire stripper
! WARNING
SHOCK HAZARD
damage to the equipment.
MOUNTING HOLES
TABLE 1
WIRING INFORMATION
1. Turn OFF power to the unit.
2. If an existing thermostat is being
replaced:
a. Remove the existing thermostat
from wall.
b. Disconnect wires from the existing
thermostat, one at a time,
recording wire color and terminal
marking as you go.
TERMINAL
Y2
SECOND-STAGE COOLING (EXTERNAL TO FURNACE)
24V
NOT USED
24V(C)
3. Separate the front plastic assembly
of the thermostat from the subbase.
4. Route the thermostat wires through
the wire opening in the subbase.
Mark the location of the mounting
holes you will be using.
TO "C" TERMINAL, IFC BOARD. TRANSFORMER 24V COMMON
G
TO "G" TERMINAL, IFC BOARD. INDOOR BLOWER.
Y1
TO "YH" TERMINAL, IFC BOARD. COOLING TERMINAL.
W
TO "W" TERMINAL, IFC BOARD. HEATING TERMINAL.
R
c. Discard or recycle old thermostat.
NOTE: Mercury is a hazardous
waste and MUST be disposed of
properly. Consult local codes for
proper disposal methods.
FUNCTION
TO "R" TERMINAL, IFC BOARD. TRANSFORMER 24V SUPPLY
SN(G)
COMMON TERMINAL FOR ALL REMOTE TEMPERATURE
SENSORS.
SN(R)
POWER SUPPLY TERMINAL FOR REMOTE INDOOR
TEMPERTAURE SENSOR. NOT USED IF REMOTE SENSOR IS
NOT USED.
W2
V
SN(O)
NOT USED.
TO "V" TERMINAL, IFC BOARD. PERMITS GAS VALVE
MODULATION. ONLY USED WITH MODULATING HEAT
FURNACES.
POWER SUPPLY TERMINAL FOR REMOTE INDOOR
TEMPERATURE SENSOR. NOT USED IF REMOTE SENSOR IS
NOT USED.
5. Drill two 3/16-in. mounting holes in
the marked locations.
6. Secure the subbase to the wall with
the 2 anchors and screws provided
with the thermostat. Make sure that
all wires extend through the wire
opening in the subbase.
7. Connect wires to the proper terminal
locations on the subbase (see Table
1 and Figures 2 & 3).
8. Push any excess wire back into the
wall and seal the hole to prevent air
leaks. Leaks can affect thermostat
operation.
9. Snap the thermostat together,
making sure assembly is secure.
10. Turn ON power to the unit.
3
THERMOSTAT WIRING
JUMPER “JW1 TWIST OFF”
FEATURE
FIGURE 2
WIRING CONFIGURATION FOR MODULATING 90 PLUS GAS FURNACES
(MODULATING HEAT / 1-STAGE COOL)
"Twist off" is written on the thermostat
printed circuit board subbase, above and
to the right of the thermostat vertical 24
volt control wiring terminals. Nearby, is a
one-time removable wiring jumper that is
ONLY removed when using 2 separate
24-volt control transformers for
independent thermostat heating and
cooling functions.
IMPORTANT: DO NOT REMOVE OR
TWIST OFF THIS JUMPER WHEN
THERMOSTAT IS USED WITH THE
MODULATING 90% FURNACE.
If the twist off jumper is inadvertently
removed. The thermostat can continue
to be used by placing a jumper wire
between the thermostat subbase "24V"
and "R" terminals. This will restore the
thermostat back to its original wiring
configuration for use with a singlecontrol transformer.
FIGURE 3
WIRING CONFIGURATION FOR REMOTE SENSORS
SN(R)
1 INDOOR SENSOR
SN(O)
1 OUTDOOR SENSOR
REMOTE INDOOR/OUTDOOR
TEMPERATURE SENSOR
(PART # 41-25300-04)
The remote indoor/outdoor sensor is
designed for use with your electronic
thermostat. It is easy to install and
provides accurate digital communication
of space temperature back to the
controlling thermostat from up to 300
feet, using 2-wire, 18-gauge cable wired
directly to the thermostat subbase.
When a remote sensor is installed, the
on-board temperature sensor is
disabled. The thermostat detects the
remote sensor connection and controls
temperature based on the data received.
Up to four (4) remote locations can be
monitored. See Figure 3 for wiring
information.
IMPORTANT: USE ONLY THE
INDOOR/OUTDOOR SENSOR
DESIGNED FOR THIS THERMOSTAT
(PART # 41-25300-04). ANY REMOTE
OUTDOOR OR INDOOR SENSORS
USED WITH PREVIOUSLY INSTALLED
SYSTEMS OR DESIGNED FOR USE
WITH OTHER THERMOSTATS ARE
NOT COMPATIBLE AND CANNOT BE
USED WITH THIS THERMOSTAT.
4
SN(G)
SN(G)
MULTIPLE LOCATIONS
If using sensors in multiple locations, 4 sensors must be used.
Sensors may be grouped in one cover if only 2 or 3 locations are required.
NOTE: Wiring schematic remains the same no matter how many locations are used.
SN(R)
THERMOSTAT ADAPTER
PLATE (PART # 41-25300-06)
The thermostat adapter plate is used to
mount your electronic thermostat over a
large hole, or to cover other holes left by
the previous thermostat if you are
replacing an old thermostat.
SN(G)
THERMOSTAT
CONFIGURATION
EDITING SETTINGS
(REFER TO FIGURE 4)
1. Enter Configuration Mode by
pressing and holding the FAN button
for 10 seconds.
2. Use the UP and DOWN buttons to
change the Settings Selection
Display to the correct setting number.
3. Press the TIME/TEMP button to
switch to the Preferences Display
area.
4. Use the UP and DOWN buttons to
change your preferences as listed in
the detailed settings instructions that
follow.
5. If no further changes are needed,
press the HOLD/END button. If
further settings changes are needed,
press TIME/TEMP to toggle back to
the Setting Selection Display to
choose another setting. If no button is
pressed for 3 minutes, the thermostat
will exit Configuration Mode and
return to normal operation.
CONFIGURATION OPTIONS
Setting 1: Sensitivity adjustment
LOCAL OR REMOTE SENSOR
This selection determines whether the
thermostat uses the local on-board
temperature sensor or an optional
remote room temperature sensor.
Factory default is LS.
The sensor options are:
LS = Local Sensor
RS = Remote Sensor
SETTING 8
SETPOINT ANTICIPATOR
This selection determines when the
program schedule time takes effect. If
set to ON the thermostat will look ahead
60 minutes into the program schedule
and slowly ramp the setpoint to satisfy
demand before the program period. If
this setting is OFF the program schedule
will switch to the scheduled temperature
at the scheduled time without ramping
the setpoint. The factory default is ON.
The setpoint anticipator options are:
OFF-CYCLE DEHUMIDIFICATION (OCD)
This setting enables or disables OCD.
Factory default is ON.
The OCD feature allows the unit to run
when there has been no call for cooling
and high humidity is present. It does this
by sensing the space temperature and
comparing that to the set point
temperature. It also uses the time
elapsed since the last cooling call
ended.
Setting 13: Local sensor offset
Setting 16: Remote sensor offset
Setting 19: Outdoor sensor offset
NOTE: Settings 2, 4, 5, 6, 11, 12, 14,
15, 17, and 18 are not used on this
model.
NOTE: Do not adjust for 30 minutes
after installation because the board may
be heated by handling. The selected
number is the number of degrees, plus
or minus, which will be added to the
actual temperature. The numbers can
range between -5 and +5.
PROGRAM SCHEDULE PERIODS
This setting determines the number of
program periods in the program
schedule (2 or 4). Factory default 4.
Setting 7: Local or remote sensor
selection
Setting 10: Off-Cycle dehumidification
LOCAL SENSOR OFFSET
This setting allows the room
temperature display to be adjusted by
+/- 5 degrees. The factory default is 0.
SETTING 9
SETTING 10
Setting 9: Programming periods per day
SETTING 13
ON = Anticipate setpoint change
OFF = Do not anticipate setpoint change
Setting 3: Fahrenheit or Celsius
Setting 8: setpoint anticipator
OCD activates if the last call for cooling
ended at least 75 minutes ago and the
space temperature is below the set
point. The thermostat calls for cooling
and runs the blower at 85% of its
normal cooling CFM. This cools and
dehumidifies the space air. The
equipment runs for 15 minutes then
stops.
OCD will be canceled if the space
temperature drops 2.5°F below set
point, the thermostat mode is changed,
or if a call for cooling occurs. This
feature will not be turned on at the
factory. The homeowner must turn the
feature on for it to become active.
Check instructions supplied with the
thermostat to determine how to do this.
SETTING 7
SETTING 16
REMOTE SENSOR OFFSET
This setting allows the room
+/- 5 degrees. The factory default is 0.
SETTING 19
OUTDOOR SENSOR OFFSET
This setting allows the outdoor
+/-5 degrees. The factory default is 0.
FIGURE 4
THERMOSTAT - CONFIGURATION MODE
1
SETTING 1
2
SENSITIVITY ADJUSTMENT
This adjustment controls the cooling
sensitivity. Factory default setting for
cooling sensitivity is 8. The sensitivity
options are:
FIRST STAGE
5 = 0.5°
8 = 0.8°
12 = 1.2°
SECOND STAGE
5 = 1.0°
8 = 1.6°
12 = 2.4°
3
6
SETTING 3
FAHRENHEIT/CELSIUS
This setting operates the thermostat in
either Fahrenheit or Celsius mode.
Factory default is Fahrenheit
4
5
1. Setting Selection Display
2. Preferences Display
3. UP/DOWN Selection Buttons
4. HOLD/END Button
5. TIME/TEMP button
6. FAN button
5
THERMOSTAT OPERATION
(REFER TO FIGURE 5)
POWER UP
AUTO MODE
When power is first applied, “rh” will
appear for 5 seconds in the
Temperature Display area of the LCD
screen while the thermostat initializes.
This product can control heating/cooling
set points simultaneously using Auto
mode. Auto mode will switch between
heating and cooling as required. The
minimum difference between the
heating and cooling set points is 2
degrees.
SETTING CURRENT TIME
1. Press the TIME/TEMP button. SET
TIME will flash on the display.
2. Press the UP or DOWN buttons until
the correct time is displayed. Holding
either button down will allow the
value to scroll in the display.
3. When the correct time appears on
the display, press the HOLD/END
button. (NOTE: If you choose not to
press the HOLD/END button, the
thermostat will automatically exit the
time setting mode after 10 seconds).
SETTING CURRENT DAY
Press the DAY button to advance to the
correct day.
• Exit programming at any time by
pressing the HOLD/END button.
PROGRAMMING A COMFORT
SCHEDULE
1. Press the PROGRAM button. The
word PROGRAMMING will appear
on the display and the words SET
TIME will flash on the display. the
day of the week and the present
period icons will appear on the
display. The current mode (HEAT
or COOL) will also show. Use the
DAY button to select the desired
day and the PROGRAM button to
select MORNING.
PROGRAMMED OPERATION
The thermostat provides 2 or 4 periods
per day (MORNING, DAY, EVE, NIGHT,
or DAY, NIGHT) as configured by your
installer. Seven schedules per week
(one for each day) are available. A
separate time, heat setpoint, and cool
setpoint can be set for each period and
schedule. Set point can be set for each
period and schedule.
2. Press the UP or DOWN button to
select the cooling temperature
setpoint.
The first press of the PROGRAM button
will bring up the programming mode
and place you at the current day.
Successive presses will switch between
the four daily periods.
3. Press the MODE button until
COOL is displayed. Press
TIME/TEMP until SET TEMP
flashes on the display.
4. Press the UP or DOWN button to
select the cooling temperature
setpoint.
WHILE PROGRAMMING
MANUAL OPERATION
To operate the thermostat manually
without a pre-programmed comfort
schedule, press the HOLD/END button.
The HOLD icon will appear in the LCD
Display and the clock will be hidden to
indicate that you are no longer following
a programmed schedule.
TO SELECT THE MODE:
Use the mode button to move
between the choices. OFF, AUTO,
HEAT, or COOL will appear on the
display.
• The TIME/TEMP button will toggle
between the SET TIME and SET
TEMP modes.
• The MODE button toggles between
HEAT and COOL setpoints. These
three numbers can be programmed
for each of the periods.
TO ADJUST SETPOINT:
Pressing either the UP or DOWN
buttons once will show the current
setpoint. The current setpoint will be
displayed for a period of 5 seconds.
Successive press within 5 seconds
will adjust the setpoint. The SET
TEMP icon will flash on the LCD
Display while setpoint adjustments
are being made. Five seconds of
inactivity will return the thermostat to
room temperature display mode.
6
6. Press the Up or DOWN buttons to
select the heating temperature
setpoint.
• The DAY button changes the day of
the week.
FIGURE 5
THERMOSTAT LCD DISPLAY
1
TO SELECT THE FAN OPERATION
Use the FAN button to move
between continuous fan (indicated by
the FAN ON icon) and auto fan
operation.
TO READ ROOM TEMPERATURE:
The large display reads room
temperature until a button is pressed.
5. Press the MODE button until
HEAT is displayed. Press
TIME/TEMP until SET TEMP
flashes on the display.
2
3
10
4
9
1.
2.
3.
4.
5.
Set Temperature
Program Period
Days of Week
Time of Day
Programming Mode
8
7
6
6.
7.
8.
9.
10.
5
Set Time of Day
Temperature Display
Hold Status
Fan Status
Mode Setting
7. Press the PROGRAM button to
advance to the next time period. Enter
the remaining time and temperature
settings for the periods DAY, EVE,
and NIGHT by following steps 2
through 6 above.
ADVANCED
THERMOSTAT
OPERATION
CHECKING
THERMOSTAT
OPERATION
REFER TO FIGURE 5
REFER TO FIGURE 5
8. Press the DAY button to change
between days. To set another days
schedule, repeat steps 2 through 7.
TEMPERATURE DISPLAY
FAN OPERATION
The thermostat will display room
temperature until either the UP or
DOWN button is pressed. The words
SET TEMP will appear when these
buttons are pressed. The current
setpoint will be displayed. If no buttons
are pressed for 5 seconds, the display
will return to room temperature display
mode.
1. Press FAN button. This will start
continuous fan operation. FAN ON
icon will be displayed.
2. Press FAN button again. This will
stop continuous fan operation. The
FAN ON icon will turn off.
9. Press HOLD/END to exit the
programming mode.
COPY PREVIOUS DAY
When the last period parameters for the
current day have been programmed, the
user can press the DAY and UP buttons
simultaneously to copy the current day
schedule into the next day.
MODIFYING YOUR WEEKLY
COMFORT SCHEDULE
If you choose to change any of the
schedule settings, press PROGRAM at
any time. You will enter the programming
schedule at the present day, present
mode, in the morning period. You are
ready to set the new starting time for the
morning period. Follow the steps listed
above to change the schedule values.
OVERRIDING YOUR COMFORT
SCHEDULE
There are two ways to override your
comfort schedule:
METHOD 1—MANUAL OPERATION
Pressing the HOLD/END button will turn
on the HOLD icon. The thermostat will
maintain the current temperature
settings and ignore the comfort schedule
for an indefinite period of time. The word
HOLD will appear in the display and the
clock digits will be hidden. Press the
HOLD/END button a second time and
the thermostat will return the
temperature settings to the programmed
comfort schedule and display the clock.
Pressing HOLD/END will not alter your
programmed comfort schedule.
METHOD 2—TEMPORARY OVERRIDE
At the first press of the UP or DOWN
button, the current temperature setting
will appear on the display. Pressing the
UP or DOWN button again will
temporarily change the setpoint as
needed. At the next programmed time,
the programmed comfort schedule will
be used.
HEATING OPERATION
IF OPTIONAL OUTDOOR SENSOR IS 1. Press MODE button until HEAT is
displayed.
INSTALLED: To display the outdoor
2.
Press UP button until LCD display
temperature, press and hold the UP and
reads 3° above room temperature.
DOWN keys at the same time. Display
Press UP and FAN buttons
will return to normal after 4 seconds.
simultaneously to defeat timers.
Heating system should begin to
TIMEGUARD TIMER
operate immediately.
A 5-minute timeguard is built into the
thermostat and is initiated automatically
COOLING OPERATION
upon power up, and any time the
1. Press the MODE button until COOL
compressor turns off. The compressor
is displayed.
will not turn on until the timeguard has
expired. The timeguard affects only
2. Press the DOWN button until the
compressor operation. Pressing the UP
LCD display reads 3° below room
temperature. Press UP and FAN
and FAN buttons simultaneously
buttons simultaneously to defeat
overrides the timeguard for 1 cycle.
timers. Cooling system should begin
to operate immediately.
CYCLE TIMER
In normal heating and cooling
operation, the thermostat will not allow
more than 4 equipment cycles per hour
(or 1 cycle every 15 minutes). Both the
Y and W outputs have a 15-minute
timer that begins to count down when
the output is turned on. Pressing the UP
and FAN buttons simultaneously or
changing the setpoint will override the
timer for 1 cycle.
FIRING RATE
This thermostat mode indicates the
modulating furnace heating capacity in
5% firing rate increments ranging from
35% to 95%.
The furnace will fire at 40% capacity if
the thermostat indicates 35%, 40% or
45% heating capacity.
MINIMUM-ON TIMER
Beginning at the 50% firing rate, the
furnace fires in 5% increments up to
Once the equipment has turned on, it
will remain on for a minimum of 3
minutes regardless of demand.
However, the equipment can turn off in
less than 3 minutes if a change in
setpoint or a change in mode occurs.
The furnace fires at 90% heating
capacity at the thermostat-indicated
90% heating capacity. The furnace fires
at 100% heating capacity at the
thermostat-indicated 95% heating
capacity.
STAGING TIMER
There is a 15-minute delay between the
first and second stages of cool (i.e. Y1
to Y2).
ERROR MESSAGES
E4 will be displayed if the thermostat
has an internal memory failure. If E4
appears, replace thermostat.
-- (dashes) will be displayed if the
thermostat cannot properly read
temperature. If -- appears, replace
either the thermostat or the sensor in
error (remote or outdoor air).
NOTE: Although the furnace is actually
firing at 100% capacity, the thermostat
will not indicate over 95% heating
capacity.
1. Place thermostat in heating mode.
2. Press and hold the TIME/TEMP
button for 10 seconds until display
reads 35. Though the thermostat
may read 35%, the furnace will not
fire below 40% heating capacity.
3. To raise or lower the firing rate,
press the up or down arrows.
4. To exit, press the HOLD/END button.
7
PROGRAMMABLE THERMOSTAT TROUBLESHOOTING GUIDE
This chapter is devoted to
troubleshooting various operating
problems that may occur. It suggests
actions that may be taken to correct
problems and return the thermostat to
operational status.
To start the troubleshooting
procedure, a thorough visual
inspection must be made to
determine if the malfunction is
caused by some obvious defect (i.e.,
damaged component, loose wire
connection, etc ...).
Table 2 does not list all the
symptoms and probable causes, only
those most probable. Various
combinations of malfunctions are
also possible.
TABLE 2
PROGRAMMABLE THERMOSTAT TROUBLESHOOTING TABLE
SYMPTOM
1- No display /
faint display
3 - LCD display has
missing or extra
segments displayed
4 - Temperature
display is incorrect
5 - Fan does not
activate with the
system equipment
6 - Fan does not
turn off
7 - Thermostat will
not call for heat
8 - Thermostat will
not call for cooling
9 - Room
Temperature too
cool when set to
cooling
8
POSSIBLE CAUSE
1a- Supply voltage incorrect
1b- System transformer
weak or overloaded
1c- Thermostat damaged because
system voltage was greater than
30VAC
3a- LCD failure
4a- The thermostat is set
in either F or C display
4b- Poor thermostat location
4c- Local Sensor Offset is too high
5a- Fan failure
6a- The thermostat is in continuous
fan mode
7a- Compressor delay still in progress
7b- Thermostat temperature setpoint
is satisfied
8a- Compressor delay still
in progress
8b- Thermostat temperature
setpoint is satisfied
11a- Off-Cycle Dehumidification
feature activated
CORRECTIVE ACTION
1a- Use a voltmeter to check between the 24V and
24V(c) terminals located on the thermostat subbase.
Voltage should read between 20VAC to 30VAC. If the
voltage is less than 20VAC, disconnect the thermostat and
verify the voltage between 24V and the other equipment
wires; see possible causes 1b and 1c. If voltage is greater
than 30VAC, troubleshoot the power source and replace
the thermostat.
1b- Check and / or replace with a suitable 24 Volt
transformer
1c- Replace with new thermostat, and ensure new
thermostat is isolated from the system using suitable
relays and a transformer of the proper rating.
3a- Replace the thermostat
4a- Verify whether the thermostat is set to display °C
or °F.
4b- Relocate the thermostat to a better location.
4c- Modify Setting 13 per the instructions in this manual.
5a- Place a jumper between terminal blocks R and G.
Fan should activate. If it does not, troubleshoot the fan
system; if fan does activate, replace the thermostat.
6a- Press the Fan key to deactivate the continuous fan
mode. Fan will now activate only with equipment.
7a- Wait . . . equipment short cycle protection
in progress. To override, press the UP and FAN buttons.
7b- Raise the heating temperature setpoint
using the up arrow button.
in progress. To override, press the UP and FAN buttons.
8b- Lower the cooling temperature setpoint
using the down arrow button.
11a- Deactivate Off-Cycle Dehumidification by following the
instructions in this manual
HEAT/COOL AUTO-CHANGEOVER NON-PROGRAMMABLE
THERMOSTAT (PART #41-25347-01)
The non-programmable thermostat
complements the programmable
thermostat, but is less costly and has
fewer features. Its location, mounting,
installation, and wiring are the same as
the programmable thermostat.
However, it only displays the room
temperature, the operating mode, and
if heating or cooling is currently
operating (see Figure 6).
The user can select different
temperatures for day and night
settings. However, the thermostat must
be manually changed from one to the
other.
FIGURE 6
NON-PROGRAMMABLE
THERMOSTAT
This thermostat has five DIP switches
on the subbase. Only three of which
are functional. The subbase and
switch selections are illustrated (see
Figure 7).
This thermostat also can use remote
indoor and outdoor sensors. No battery
is needed. It can display temperatures
in either °F or °C. It can run the blower
continuously or intermittently. The user
can select off-cycle dehumidification
and multistaging features as desired.
FIGURE 7
NON-PROGRAMMABLE SUBBASE DIP SWITCH SETTINGS
DETAIL A
A
SWITCH #
1
OFF
ON
6 Minute Minimum On 4 Minute Minimum On
2
NOT USED
NOT USED
3
Humidity Control Off
Humidity Control On
4
NOT USED
NOT USED
5
Single-Stage
Multistage
9
NON-PROGRAMMABLE
THERMOSTAT
INSTALLATION
CONSIDERATIONS
You should prepare ahead if you are
installing any of the options mentioned
in other sections of this manual.
If this is a brand new installation or a
replacement, verify:
• what kind of wire is needed or is
present
• how much (distance from the
thermostat and the equipment, and
optional equipment )
• are you installing any remote sensing
equipment (please read the
installation instructions packaged
with these units before proceeding
any further)
The thermostat is to be connected
using unshielded 18 AWG minimum
thermostat wire.
LOCATION
The most important consideration in
installing your electronic thermostat is
where to locate the unit. The location
can radically affect the operation of the
thermostat. To ensure proper operation,
the thermostat should be mounted on
an inside wall, in a frequently occupied
area of the building. In addition, its
position must be at least 18 inches
(46cm) from any outside wall, and
approximately 5 feet (1.5m) above the
floor in a location with freely circulating
air of an average temperature.
BE SURE TO AVOID THE
FOLLOWING LOCATIONS:
• behind doors or in corners where
freely circulating air is unavailable
• where direct sunlight or radiant heat
from appliances might affect control
operation
• on an outside wall
• adjacent to, or in line with,
conditioned air discharge grills,
stairwells, or outside doors
• where its operation may be affected
by steam or water pipes or warm air
stacks in an adjacent partition space,
or by an area not heated or cooled
behind the thermostat
• where its operation will be affected
by the supply air of an adjacent unit
• near sources of electrical
interference such as arcing relay
contacts
10
THERMOSTAT
INSTALLATION
! WARNING
SHOCK HAZARD
damage to the equipment. Follow
all local electrical codes during
installation. All wiring must
conform to local and national
electrical codes. Improper wiring
or installation may damage this
product, electrical shock,
property damage or death.
! CAUTION
EQUIPMENT DAMAGE HAZARD
Before connecting the power
supply to finished installation,
make all wiring connections and
VERIFY all connections. Shortcircuited or improperly
connected wires will result in
permanent damage to the unit
IMPORTANT: WHEN REPLACING
AN EXISTING THERMOSTAT, USE
WIRE TAGS TO IDENTIFY
TERMINAL DESIGNATIONS AS YOU
DISCONNECT THE UNIT.
1. Lift the thermostat access cover
and insert a coin (or a large flat
blade screwdriver) into the slot
located in the bottom center of the
case and twist 1/4 turn. Be
extremely careful not insert into
the casing, as this may damage
the circuit board. Grasp the lower
corner of the thermostat body and
separate from the thermostat
backplate. Swing the thermostat
out from the bottom, and lift up
and out of the base.
2. Place the rectangular opening on
the thermostat backplate over the
equipment control wires protruding
from the wall. Using the base as a
template, mark the location of the
two (2) mounting holes. No
leveling is required.
3. Use the supplied anchors and
screws for mounting on the
drywall or plaster. Drill two (2)
3/16” (5mm) holes at the marked
locations, tap nylon anchors flush
to the wall surface. Fasten the
backplate to the wall.
4. Connect the wires from your
equipment to the thermostat
terminal blocks as shown in Table
2 and Figures 8 and 9.
TABLE 3
OUTPUT TERMINAL DESIGNATIONS
TERMINAL
FUNCTION
Y2
Energizes on a call for 2nd stage cooling
V
Modulating heat output
W
Energizes on a call for heat
Y1
Energizes on a call for cooling
G
Fan is energized with a call for heating or cooling, or pressing the Fan key on
the thermostat
R*
Independent switching voltage (Typically jumpered to 24V)
24V *
24VAC from equipment transformer
24V(c)
24VAC Common from equipment transformer
RS2
RS1
RS+V
Use to connect outdoor temperature sensor (SL-ODT) option and / or indoor
remote sensor(s) (SL-IDS) option. Refer to the instructions included with the
sensors.
FIGURE 8
WIRING DIAGRAM FOR MODULATING HEAT / 1 STAGE COOL
FIGURE 9
WIRING DIAGRAM FOR MODULATING HEAT / 2 STAGE COOL
11
RE-ASSEMBLING THE
THERMOSTAT BODY AND
ACCESS PANEL TO THE
INSTALLED BACKPLATE
FIGURE 10
RE-ASSEMBLING THERMOSTAT TO BACKPLATE
Before the thermostat is re-assembled
to the backplate, install the optional
indoor/outdoor remote sensors, if used.
Refer to the installation instructions
supplied with each option. Also, verify
the positions of the DIP switches on the
back of the thermostat body.
1. Position the thermostat inside the
access panel. See Figure 10.
2. Position the assembly on the hinged
tabs located at the top of the
installed backplate.
3. Gently swing the thermostat and
access cover downwards and press
on the bottom center edge until it
snaps into place.
NOTE: If you have
installed the optional
lock pin, you will
notice the clear
plastic tab snap into
the slot located on the
access panel.
TEMPERATURE
ACCURACY
Full temperature accuracy will only be
realized after the thermostat has been
installed and powered for at least one
(1) hour.
YOUR THERMOSTAT KEYS
You may select different heating and
cooling setpoints for the system to
maintain, e.g. 70° in heating and 75°
in cooling. Raising or lowering the
setpoints in heating or cooling is as
simple as pushing a button. This
section will describe the function of
each of the keys which make up the
thermostat’s keyboard and walk you
through setting up when (and why)
you want your heating and cooling
equipment to be activated.
12
THE OUTDOOR KEY
THE DAY/NIGHT KEY
This key allows the thermostat to
display the outdoor temperature, if
your thermostat has been installed
with an optional electronic outdoor
remote temperature sensor.
This key switches the thermostat
between day and night temperature
settings.
This key allows to select between
the four (4) modes available: Heat ,
Cool , Auto
, Off. The words
(accompanied by their appropriate
symbols) Heat, Cool, and Auto are
displayed for five seconds. The
words HEAT and Off remain visible.
THE FAN KEY
This key allows to select between
continuous fan mode or auto fan
mode. The continuous fan mode
constantly displays the
symbol;
auto fan mode refers that the fan
(and
symbol) only activates (is
displayed) when your heating or
cooling equipment has been
activated.
>
<
AND KEYS
When used with a combination of
other keys, are used to scroll
backward or forward through
temperature setpoints). They can
also choose between °C or °F.
Press the or keys at the same
time to change the temperature
value from Celsius (°C) to Fahrenheit
(°F), and vice versa.
>
THE MODE KEY
THE
<
The thermostat normally displays
room temperature (°F or °C), mode
of operation, and whether the fan is
in use or not. The six keys on the
front of the unit allow complete
control of your heating and cooling
equipment. This document will go
into detail on the function of each of
the ten keys. If you are already
familiar with the thermostat, you
need only refer to the pad-printed
instructions located on the inside of
the thermostat door.
OPTIONAL FEATURES AND
EQUIPMENT FOR NONPROGRAMMABLE
THERMOSTATS
FIGURE 11
THERMOSTAT ADAPTER PLATE
The following are some of the options
available for your electronic thermostat,
to further enhance and expand its
capabilities.
THERMOSTAT ADAPTER PLATE
(PART # 41-25300-01)
The thermostat adapter plate (See
Figure 11) is used to mount your
electronic thermostat over a large hole,
or to cover other holes left by the
previous thermostat if you are replacing
an old thermostat. Simply drill out the
holes marked “A”, line the thermostat
backplate holes with those already
drilled out, and follow the standard
installation instructions.
REMOTE INDOOR
TEMPERATURE SENSOR (PART
# 41-25300-02)
The remote indoor sensor (See Figure
12) is designed for use with your
electronic thermostat. It is easy to
install and provides accurate digital
communication of space temperature
back to the controlling thermostat from
up to 300 feet, using 3-wire unshielded
cable (maximum of 100 feet if using
shielded cable) wired directly to the
thermostat (RS2, RS1, and RS+V).
When a remote indoor sensor is
installed, the on-board temperature
sensor is disabled. The thermostat
detects the remote sensor connection
and controls temperature based on the
data received. You may connect up to
six (6) (and a optional remote outdoor
temperature sensor) in daisy-chain for
temperature averaging.
FIGURE 12
REMOTE INDOOR TEMPERATURE SENSOR
FIGURE 13
REMOTE OUTDOOR TEMPERATURE SENSOR PACKAGE
OUTDOOR TEMPERATURE
SENSOR (PART # 41-25300-03)
The remote outdoor sensor package
(See Figure 13) is designed for use
with the Contour Comfort Control
thermostat. The sensor package is
comprised of two (2) pieces: the indoor
thermostat interface and the outdoor
probe. It is easy to install and provides
accurate digital communication of
outdoor temperature back to the
controlling thermostat from up to 300
feet, using 3-wire unshielded cable
(maximum of 100 feet, if using shielded
cable). There are no switches to set.
The sensor may be connected directly
to the electronic thermostat or wired
directly to one of up to six optional
indoor remote sensors.
13
NON-PROGRAMMABLE THERMOSTAT TROUBLESHOOTING GUIDE
This chapter is devoted to
troubleshooting various operating
problems that may occur. It suggests
actions that may be taken to correct
problems and return the thermostat to
operational status.
To start troubleshooting
procedure,
a thorough visual inspection must be
made to determine if the malfunction
is caused by some obvious defect
(i.e., damaged component, loose
wore connection, etc.)
Table 4 does not list all the
symptoms and probable causes, only
those most probable. Various
combinations of malfunctions are
also possible. The procedures are
complete only up to being
correctable.
TABLE 4
NON-PROGRAMMABLE TROUBLESHOOTING TABLE
SYMPTOM
1- No display /
faint display
2- “AC” is
on the LCD display
3- LCD display has
missing or extra
segments displayed
4- Temperature
display is incorrect
5- Fan does not
activate with the
system equipment
6- Fan does not
turn off
7- Thermostat will
not call for heat
8- Thermostat will
not call for cooling
9- Minimum
equipment ON time
too long, causing
overshoot
10- Minimum
equipment ON time
too short
11- Room
Temperature too
cool when set to
cooling
14
POSSIBLE CAUSE
1a- Supply voltage incorrect
1b- System transformer
weak or overloaded
1c- Thermostat damaged because
system voltage was greater than
30VAC
2a- 20 - 30VAC absent from R and
C terminals, located on the
thermostat backplate
3a- LCD failure
4a- The thermostat is set
in either F or C display
4b- Poor thermostat location
5a- Fan failure
6a- The thermostat is in continuous
fan mode
7a- Compressor delay still in progress
7b- Thermostat temperature setpoint
is satisfied
8a- Compressor delay still
in progress
8b- Thermostat temperature
setpoint is satisfied
9a- DIP switch #2 is in
the ON position
(manufacturer’s default)
10a- DIP switch #2 is in
the OFF position
11a- Off-cycle dehumidification
feature activated
CORRECTIVE ACTION
1a- Use a voltmeter to check between the 24V and
24V(c) terminals located on the thermostat backplate.
Voltage should read between 20VAC to 30VAC. If the
voltage is less than 20VAC, disconnect the thermostat and
verify the voltage between 24V and the other equipment
wires; see possible causes 1b and 1c. If voltage is greater
than 30VAC, troubleshoot the power source and replace
the thermostat.
1b- Check and / or replace with a suitable 24 V
transformer
1c- Replace with new thermostat, and ensure new
thermostat is isolated from the system using suitable
relays (INT-43) and a transformer of the proper rating.
2a- Using a voltmeter, measure the voltage between
the 24V and 24V(c) terminal blocks. If the reading is
less than 20VAC, check system transformer. If the voltage
is between 20 and 30VAC, replace the thermostat.
3a- Replace the thermostat
4a- Verify whether the thermostat is set to display °C
or °F.
4b- Relocate the thermostat to a better location.
5a- Place a jumper between terminal blocks R and G.
Fan should activate. If it does not, troubleshoot the fan
system; if fan does activate, replace the thermostat.
6a- Press the Fan key to deactivate the continuous fan
mode. Fan will now activate only with equipment.
in progress.
7b- Raise the heating temperature setpoint
using the key.
in progress.
8b- Lower the cooling temperature setpoint
using the … key.
9a- Place DIP switch #2 to the ON
position. This will decrease minimum
equipment ON time from 6 minutes to 4
minutes.*
10a- Place DIP switch #2 to the OFF position.
This will increase minimum equipment ON
time from 4 minutes to 6 minutes.*
11a- Place DIP switch #4 to the OFF position.
15
16
SECTION 3
FOR MODULATING CONDENSING GAS FURNACES
! Recognize this symbol as an indication of Important Safety Information!
!
WARNING
IF THE INFORMATION IN THESE INSTRUCTIONS
IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
!
FOR YOUR SAFETY
— Do not store or use gasoline or other flammable
vapors and liquids, or other combustible materials
in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the
fire department.
• Do not rely on smell alone to detect leaks. Due
to various factors, you may not be able to smell
fuel gases.
• U.L. recognized fuel gas and CO detectors are
recommended in all applications, and their
installation should be in accordance with the
manufacturer’s recommendations and/or local
laws, rules, regulations, or customs.
— Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
NOTE TO INSTALLER: REVIEW THIS
MANUAL WITH THE USER AND LEAVE
IT WITH THE EQUIPMENT.
!
WARNING
PROPOSITION 65: THIS PRODUCT CONTAINS
CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS
OR OTHER REPRODUCTIVE HARM.
DO NOT DESTROY. PLEASE READ
CAREFULLY AND KEEP IN A SAFE
PLACE FOR FUTURE REFERENCE.
92-20802-71-06
INTRODUCTION TO YOUR FURNACE
Thank you for the purchase of your new modulating gas furnace! This furnace is designed to be the ultimate in heating
comfort and is the only true modulating gas furnace available
on the market today.
The modulating gas furnace provides a superior level of
comfort due to the interaction of seven basic components:
• Variable Output Thermostat - Whereas conventional thermostats only send an On/Off signal to the furnace, the thermostat for the modulating furnace system is specially
designed to indicate the exact heating requirements of the
conditioned space. This is accomplished by a logic control
routine that accurately senses the space load, minimizes
recovery times, reduces temperature swings and optimizes
system efficiency and performance.
• Modulating Gas Valve - The gas valve has the conventional redundant solenoid valves for inherent safety, but also has
a third operator for capacity control. This operator is actually
a servo valve which varies the input rate of the furnace proportionally to the signal from the controller. The modulating
furnace can operate anywhere from 40% to 100% of the
nameplate input of the furnace.
• Furnace Controller - The furnace controller provides all of
the ignition and safety functions of the typical IFC as well as
interpreting the signals from the thermostat. The furnace
controller will optimize furnace performance by monitoring all
thermostat and temperature inputs and insuring the stable
operation of the inducer, gas valve and indoor blower motor.
• ECM Variable Speed Blower - The airflow through the duct
work is varied to meet the load demand. Airflow as low as
300 CFM is achieved by the response of a brushless permanent magnet variable speed blower motor.
• Two Speed Draft Inducer - To insure clean combustion
and peak efficiency, the induced draft motor speed is adjusted based on the gas valve setting to provide the proper
amount of combustion air to the burners.
FIGURE 1
FIGURE 2
UPFLOW FURNACE
DOWNFLOW FURNACE
I678
ITEM
NO. PART NAME
2
ITEM
NO. PART NAME
ITEM
NO. PART NAME
1
CONDENSATE TRAP
14
TOP PLATE
1
GAS VALVE
2
DOOR SWITCH
15
BURNER
2
CAPACITOR
3
JUNCTION BOX
16
IGNITER
3
LOW PRESSURE SWITCH
4
TRANSFORMER
17
4
5
LOW PRESSURE SWITCH
18
GAS VALVE
5
BLOWER HOUSING
6
19
CAPACITOR
6
POWER FACTOR CHOKE
7
EXHAUST TRANSITION
20
7
BLOWER MOTOR
8
CONNECTOR
21
POWER FACTOR CHOKE
8
DOOR SWITCH
9
MAIN LIMIT
22
IGNITION CONTROL
9
JUNCTION BOX
10
EXHAUST AIR PIPE
23
10
11
VENT CAP PLUG
24
BLOWER MOTOR
11
HALC
12
FLAME SENSOR
25
R/A SENSOR
12
TOP PLATE
13
26
BLOWER HOUSING
13
RETURN AIR SENSOR
ITEM
NO. PART NAME
14
15
16
17
18
19
20
21
22
23
24
25
26
27
VENT CAP PLUG
EXHAUST AIR PIPE
TRANSFORMER
IGNITION CONTROL
CONNECTOR
EXHAUST TRANSITION
MAIN LIMIT
CONDENSATE TRAP
IGNITER
BURNER
FLAME SENSOR
• Return and Supply Air Sensors - These two thermister
assemblies, a factory installed return air sensor and a field
installed air probe, communicate the furnace temperature
rise to the integrated furnace control. The integrated furnace
control uses this information to calculate field conditions during calibration to insure optimal efficiency and comfort during
normal operation.
nance, this furnace will operate superbly year after year.
Please take the time to fill out the information below and
read this manual to familiarize yourself with operation, maintenance schedule, and safety operation.
IMPORTANT: READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING TO OPERATE THIS
FURNACE.
This furnace has been designed to give you many years of
efficient, dependable home comfort. With regular mainte-
INSTALLATION INFORMATION
Date Installed
AC SYSTEM
Dealer Name
Model No.
Address
Serial No.
City
INDOOR COIL
State
Zip
Telephone No.
Model No.
Serial No.
FURNACE
Model No.
Serial No.
SAFETY PRECAUTIONS
SIGNAL WORDS
There are some safety precautions
which must be understood and followed by all users of equipment such
as your furnace, where flames, gas,
electricity and rotating parts are present. To alert you to the above potential hazards, we use the signal words
“WARNING” and “CAUTION” throughout this manual and safety labels
attached to the furnace.
Read carefully and pay special attention to all warnings and cautions in this
manual. They are defined and
designed as follows to help you recognize and avoid the potential hazards of
operating this furnace:
!
WARNING
Indicates a potentially hazardous
situation which, if not avoided,
could result in property damage,
serious injury or death.
!
CAUTION
Indicates a potentially hazardous
situation which, if not avoided,
could result in property damage,
or minor or moderate injury.
POSSIBILITY OF FIRE OR
EXPLOSION
! WARNING
THIS FURNACE OPERATES BY
BURNING GAS INSIDE YOUR
HOME. THIS CREATES THE POSSIBILITY OF FIRE OR AN EXPLOSION WHICH CAN RESULT IN
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH. YOU MUST
READ AND FOLLOW ALL OF
THESE SAFETY PRECAUTIONS
TO HELP ENSURE SAFE OPERATION OF YOUR FURNACE.
• Do not test for gas leaks with a match
or flame.
• Do not use this furnace with any other
gas than the one listed on the rating
plate.
• Follow the furnace lighting instructions carefully to be sure all gas
fumes are cleared before lighting the
furnace.
• Check carefully for gas before lighting
a furnace. Do not rely on smell alone
to detect gas. Use a UL recognized
fuel gas detector and a soap and
water solution on the pipes to check
for gas leaks.
• A damaged gas control knob can
cause gas to leak. Do not hit or damage the knob. Do not force the knob
with tools. Use only your hand to turn
it to “ON” or “OFF”. Call the a quali-
•
•
•
•
•
•
fied installer, service agency or the
gas supplier immediately if you have
problems turning the knob.
Should overheating occur, or the gas
valve fail to shut off the gas supply,
turn off the manual gas valve to the
furnace before turning off the electrical supply.
Soot buildup indicates a serious combustion problem that requires immediate correction. Turn the gas supply
“OFF” until the furnace is repaired.
Contact a qualified installer, service
agency or the gas supplier immediately to inspect the furnace.
Do not place, store or use gasoline or
other flammable vapors and liquids
on, against, or around the furnace
jacket.
Do not store combustible materials
near the furnace. The furnace must
have adequate clearances from all
combustible materials such as clothing, paper, cardboard, wood or cleaning materials to prevent them from
igniting.
Keep any furnace installed in an attic
or other insulated space free and
clear of insulating material. Examine
the furnace area when installing the
furnace or adding insulation. Some
materials may be combustible.
Any additions, changes or conversions required in order for the furnace
to satisfactorily meet the application
needs should be made by a qualified
installer, service agency or the gas
supplier, using factory specified or
3
approved parts. Read your Warranty.
Contact the WARRANTOR for conversion information. This furnace was
equipped at the factory for use on
NATURAL GAS ONLY. Conversion
to LP GAS requires a special kit supplied by the WARRANTOR.
• If you desire to operate your system
with constant air circulation, consult
your thermostat manual or please ask
advice from a qualified installer, service
agency or the gas supplier.
FIGURE 4
STANDARD HORIZONTAL
DIRECT VENTING
IMPORTANT: FOR COMPLETE
OPERATION AND SET UP OF YOUR
THERMOSTAT REFER TO THE MANUAL INCLUDED IN THE LITERATURE
PACKET SHIPPED WITH THIS FURNACE.
DANGER FROM
ASPHYXIATION
! WARNING
THIS FURNACE OPERATES BY
BURNING GAS INSIDE YOUR
HOME. IMPROPER OR INCOMPLETE BURNING OF THIS GAS
CAN RESULT IN THE FORMATION
OF CARBON MONOXIDE. IF
INTRODUCED INTO THE LIVING
SPACE, THIS CAN CAUSE DIZZINESS, NAUSEA, OR DEATH BY
ASPHYXIATION. YOU MUST
READ AND OBSERVE THE SAFETY RULES BELOW TO PREVENT
OXYGEN DEPLETION OR
UNBURNED GAS OR COMBUSTION FROM ESCAPING INTO THE
LIVING SPACE OF YOUR RESIDENCE.
• Do not operate this furnace without
provisions for an adequate combustion air supply.
• Do not allow snow, ice, or any other
debris to accumulate in or around the
exhaust and intake terminations of
this furnace. These are extended
through the roof or horizontally
through the sidewall of the structure.
See Figures 3 & 4. Blockage of the
intake and exhaust can result in inad-
FIGURE 3
STANDARD VERTICAL
DIRECT VENTING
STARTING YOUR
FURNACE
LIGHTING INSTRUCTIONS
I407
equate combustion air as well as
inadequate unit performance or nuisance tripping.
• Prevent flue gases from escaping into
your residence. Deterioration of the
venting system, or soot build-up can
cause leaks into the system. Have a
qualified installer, service agency or the
gas supplier replace damaged parts or
repair obstructions in a deteriorated
vent system immediately.
• Do not use this furnace if any part has
been under water. A flood-damaged
furnace is extremely dangerous.
Attempts to use the furnace can result
in fire or explosion. A qualified service
agency should be contacted to inspect
the furnace and to replace all gas controls, control system parts, electrical
parts that have been wet or the furnace,
if deemed necessary.
• To prevent carbon monoxide poisoning,
all blower doors and compartment covers must be replaced after the furnace
is serviced. Do not operate the unit
without all panels and doors securely in
place.
SYSTEM OPERATION
INFORMATION
• Keep the air filters clean. Your heating
system will operate more efficiently and
provide better heating, more economically.
• Arrange your furniture and drapes so
that the supply air registers and return
air grilles are unobstructed.
• Close doors and windows. This will
reduce the heating load on your system.
• Avoid excessive use of exhaust fans.
I407
4
• Do not permit the heat generated by
television, lamps, or radios to influence
the thermostat operation.
This appliance is equipped with a direct
spark ignition device. This device lights
the main burners each time the room
thermostat calls for heat. DO NOT try to
light the burner by hand. See lighting
instructions on the furnace.
1. Remove the burner access door.
2. Set the thermostat to the lowest setting.
3. Turn the gas control knob counterclockwise to the “ON” position.
4. Replace the burner access door.
5. Turn on the electrical power.
6. Set the room thermostat to a point
above the room temperature to light
the main burners. After the burners are
lit, set the room thermostat to a desired
temperature.
! WARNING
BE SURE THAT THE MANUAL GAS
CONTROL HAS BEEN IN THE “OFF”
POSITION FOR AT LEAST FIVE
MINUTES. DO NOT ATTEMPT TO
MANUALLY LIGHT THE MAIN
BURNERS. FAILURE TO FOLLOW
THIS WARNING CAN CAUSE A
FIRE OR AN EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
7. If the appliance will not operate, follow
the instructions “To Turn Off Gas To
The Appliance” and call your service
technician or gas supplier.
TO TURN OFF GAS TO THE
APPLIANCE
! WARNING
SHOULD OVERHEATING OCCUR
OR THE GAS SUPPLY FAIL TO
SHUT OFF, SHUT OFF THE MANUAL GAS VALVE TO THE APPLIANCE BEFORE SHUTTING OFF
THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN CAUSE AN
EXPLOSION OR FIRE RESULTING
IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
IMPORTANT: SHUT OFF THE MANUAL
GAS VALVE LOCATED IN THE GAS
SUPPLY PIPING OUTSIDE THE FURNACE CASING.
1. Set the thermostat to the lowest setting.
2. Turn off all electric power to the appliance on which service is to be performed.
3. Remove the burner access door.
4. Turn the gas control knob to the “OFF”
position.
5. Replace the burner access door.
SEQUENCE OF
OPERATION
Heating Cycle Initiation
24 volt signal on W of the thermostat.
When the controller senses 24 volts on
W, the following sequence occurs:
• High and low pressure switches are
checked to insure contacts are open.
• Inducer is powered on high speed for a
thirty (30) second prepurge.
• Pressure switches are monitored as
the inducer creates the vacuum to
close the contacts.
• The servo valve on the gas valve is
energized with ~180 milliamps current.
(No flow yet.)
• The controller sends 120 volts to the
ignition control, which sparks across
the electrodes.
• The main solenoids on the gas valve
are energized allowing gas to flow to
the burners.
• When flame is proven, the ignition control is de-energized - 8 second maximum trial time.
MODULATING FUNCTION:
(“W” and “V” signal inputs)
After the warm-up period, the furnace will
respond to the thermostat demand by
adjusting the gas valve pressure and
blower speed anywhere between 40% to
TWO-STAGE FUNCTION:
(“W” and “W2” inputs)
adjusting the gas valve pressure and
blower heating speeds to the W signal
values. “W” only = 40% gas valve pressure and blower heating speed. “W” and
“W2” = 100% gas valve pressure and
blower heating speed.
SINGLE-STAGE
(“W” signal only)
maintaining the gas valve pressure and
blower speed at 100%.
Heating Cycle Termination
When the 24 volt signal is removed from
W1, the heating cycle will end and the furnace will shut down and return to the proper
off cycle operation.
• The gas valve maintains 100% rate
through the warm-up period - 20 seconds.
Heating Cycle Response
24 volt signal on W1. When the controller
senses 24 volts on W1, the following
sequence occurs:
MAINTENANCE
IMPORTANT: IT IS RECOMMENDED
THAT AN ANNUAL INSPECTION OF
YOUR FURNACE BE MADE BY A
QUALIFIED INSTALLER, SERVICE
AGENCY OR THE GAS SUPPLIER.
DURING THE ANNUAL INSPECTION,
IT IS RECOMMENDED THAT 120VAC
POWER BE TURNED OFF, THEN
BACK TO THE ON POSITION.
REAPPLYING120VAC INITIATES A
CALIBRATION CYCLE TO ENSURE
OPTIMUM SYSTEM OPERATION.
!
WARNING
THIS FURNACE CONTAINS MOVING/ROTATING COMPONENTS
AND USES HOUSEHOLD ELECTRICAL CURRENT. FOLLOW THE
SAFETY RULES BELOW TO
AVOID CUTS, BURNS OR ELECTRICAL SHOCK WHICH CAN
RESULT IN SEVERE PERSONAL
INJURY OR DEATH.
POSSIBILITY OF BURNS
OR ELECTRICAL INJURY
• Do not perform any service or maintenance on the furnace while it is operating. Read and follow the service
instructions provided with this furnace
before beginning any service or maintenance work.
• Do not open the blower compartment,
disassemble, or remove any components while the furnace is operating.
This may expose sharp edges or
points which could cause cuts, hot
surfaces which could cause burns,
and electrical circuits which could
cause shocks.
! CAUTION
DO NOT OPERATE YOUR SYSTEM FOR EXTENDED PERIODS
WITHOUT FILTERS. A PORTION
OF THE DUST ENTRAINED IN
THE AIR MAY TEMPORARILY
LODGE IN THE AIR DUCT RUNS
AT THE SUPPLY REGISTERS.
ANY RECIRCULATED DUST WILL
BE HEATED AND CHARRED BY
CONTACT WITH THE FURNACE
HEAT EXCHANGER. THIS
RESIDUE WILL SOIL CEILINGS,
WALLS, DRAPES, CARPETS AND
OTHER HOUSEHOLD ARTICLES.
• Instruct children on the safety hazards associated with furnaces. Keep
children away from the furnace at all
times.
FILTER MAINTENANCE
5
Have your qualified installer, service
agency or the gas supplier instruct you
on how to access your filters for regular maintenance.
FILTER IN BOTTOM OR SIDE
LOCATION
1. Remove the blower compartment
access door.
DRAFT BLOWER MOTOR. ADDITION
OF LUBRICANTS CAN REDUCE THE
MOTOR LIFE AND VOID THE WARRANTY.
• Keep air filters clean at all times.
Vacuum dirt from filter, wash with
detergent and water, air dry thoroughly and reinstall.
2. Disengage the filter retaining rod and
pull filter out.
The blower compartment and motor
should be inspected and cleaned periodically by your qualified installer, service agency or the gas supplier to prevent the possibility of overheating due
to an accumulation of dust and dirt on
the windings or on the motor exterior.
And, as suggested elsewhere in these
instructions, keep the air filters clean
because dirty filters can restrict airflow
and the motor depends on sufficient air
flowing across and through it to keep it
from overheating.
• After filters are cleaned and returned
to the furnace, be sure doors are
properly reinstalled. If you are not
totally sure of this procedure, consult
qualified installer, service agency or
the gas supplier.
REMOVING FILTERS
3. Clean filter and reinstall.
4. Replace the blower compartment
access door.
LUBRICATION
motor are permanently lubricated by the
manufacturer and do not require further
attention.
IMPORTANT: DO NOT ATTEMPT TO
LUBRICATE THE BEARINGS ON THE
BLOWER MOTOR OR THE INDUCED
COMBUSTION AIR AND
VENT SYSTEM
1. It is recommended that an annual
inspection of your furnace’s combustion air and vent system be done by
a qualified installer, service agency
or the gas supplier.
FIGURE 5
UPFLOW SIDE FILTER LOCATION
!
WARNING
IF DIRT, RUST, SOOT OR SCALE
ACCUMULATIONS ARE PRESENT,
DO NOT OPERATE THE FURNACE.
INSPECT THE HEAT EXCHANGER
FOR LEAKS. LEAKS CAN CAUSE
TOXIC FUMES TO ENTER THE
HOME AND CAUSE CARBON
MONOXIDE POISONING OR DEATH.
2. Turn OFF the electrical supply to the
furnace and remove the access
doors.
3. Inspect the gas burners for dirt, rust
or scale and clean as necessary.
I332
FIGURE 6
UPFLOW BOTTOM FILTER INSTALLATION
4. Inspect the flue connection area and
vent pipe. Be sure that the vent connector is in place and slopes upward
and is physically sound, without
holes or excessive corrosion.
5. Be sure that the return air duct connections are physically sound, are
sealed to the furnace casing and terminate outside the space containing
the furnace.
!
WARNING
CHECK THE VENT PIPE SECTIONS
FOR DETERIORATION AND CHECK
JOINT FITTINGS FOR THEIR
INTEGRITY. IF IT HAS BECOME
DISCONNECTED TOXIC FUMES
CAN ENTER THE HOME AND
CAUSE CARBON MONOXIDE POISONING OR DEATH. DO NOT
OPERATE THIS FURNACE. APPROPRIATE SERVICE MUST BE
APPLIED.
ADS-5422-01
6
6. Be sure the physical support of the
furnace is sound, without sags, cracks,
etc. around the base so as to provide
a seal between the support and the
base.
FIGURE 7
DOWNFLOW FILTER INSTALLATION
7. Look for the obvious signs of deterioration of the furnace.
8. If the furnace is free of the above conditions, replace the access doors and
restore electrical power to the furnace.
9. Start the furnace and observe its operation. Watch the burner flames to see
if they are bright blue. If a suspected
malfunction is observed, or the burner
flames are not bright blue, call for
appropriate service.
CONDENSATE
This furnace is equipped with a pressure
switch which will shut off the main burners if the condensate drain line becomes
blocked.
Be sure this condensate drain line does
not become blocked or plugged. Visual
inspection of the condensate flow can
easily be made while the furnace is in
operation. Use a flashlight to illuminate
the discharge end placed in the sewer
opening. See Figures 8 & 9.
Clean and flush the condensate tube to
make sure condensate flows freely while
the furnace is in operation.
THAT AT THE BEGINNING OF THE
HEATING SEASON, THE CONDENSATE TRAP BE INSPECTED BY A
QUALIFIED INSTALLER, SERVICE
AGENCY OR THE GAS SUPPLIER FOR
DEBRIS OR BLOCKAGE. A BLOCKED
CONDENSATE TRAP CAN CAUSE
WATER TO BACK UP INTO THE PRIMARY HEAT EXCHANGER AND LEAD
TO NUISANCE TRIPPING OF THE
OVER TEMPERATURE SWITCHES OR
PRESSURE SWITCHES.
THAT AT THE BEGINNING OF THE
HEATING SEASON THE CONDENSATE
NEUTRALIZER, IF USED, BE
REPLACED BY A QUALIFIED
INSTALLER, SERVICE AGENCY OR
THE GAS SUPPLIER.
A087001.S01
FIGURE 8
UPFLOW CONDENSATE DRAIN
REFER TO
INSTALLATION
MANUAL.
MARKINGS
It is recommended that an annual
inspection and cleaning of all furnace
markings be made to assure legibility.
Attach a replacement marking, which can
be obtained through the distributor, if any
are found to be illegible or missing.
AO51601
7
FIGURE 9
DOWNFLOW CONNECTION
REFER TO INSTALLATION
MANUAL
OVERFLOW LINE
(REQUIRED ONLY WHEN
CARTRIDGE IS USED.)
A0850-01
8

92-24161-20 Rev. 11 RGFD Modulating Furnace Installaiton

Transcription

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